Absorbent articles with multilayer dual laminates

ABSTRACT

An absorbent article comprising a topsheet, an outer cover, at least one chassis component, and an absorbent core disposed between the topsheet and the outer cover, wherein at least one of the outer cover or chassis component comprises a dual bilaminate comprising two bilaminates combined, wherein each bilaminate comprises at least one nonwoven layer and at least one multilayer film, and wherein the dual bilaminate has at most about 90 grams per square meter basis weight.

TECHNICAL FIELD

The present invention relates to multilayer laminates useful forincorporation into absorbent articles.

BACKGROUND

Absorbent articles such as conventional taped diapers, pull-on diapers,training pants, incontinence briefs, and the like, offer the benefit ofreceiving and containing urine and/or other bodily exudates. Suchabsorbent articles can include a chassis that defines a waist openingand a pair of leg openings.

Current diaper chassis are made of numerous individual polymericcomponents that vary not only in terms of their properties, but also intheir shape or form. They can be, for example, fibers, strands, fabrics,or films that can possess properties ranging from plastic toelastomeric. For example, plastic films can be found in outer covers andcan be made breathable with the use of embedded fillers.

Elastomeric films can be found in back ears and side panels, which helpsestablish improved fit. The elastomeric films may be perforated toprovide airflow that helps maintain skin health. Elastic strands can betypically found in the waist and leg band features and can be combinedwith nonwovens while under large strain to provide high-performancestretch in a gathered state. Also, plastic fibers may appear in the formof nonwoven fabrics and can be found in virtually all components of thediaper chassis, typically made of either carded or spunbond fibers andthermally bonded together to form the desired fabrics.

In order to produce stretch in materials, as mentioned, elastic strandscan be combined with inelastic nonwovens while held under large strains(so called “live stretch”). Live stretch obtained with either elasticstrands or elastic films are virtually always constructed in the machinedirection (MD) with pre-straining prior to assembling them with theinelastic nonwoven layers, using either strips or adhesive or viathermal point bonding. These have been extensively used in the trade andappreciated for the texture appearance of the gathered nonwovens, butend up using large amounts of nonwoven, and thus may not be the mostcost-effective route. An alternative to live stretch constructions areso called “zero-strain” constructions, where mechanical activation isused to apply large strains to a laminate that is comprised of anelastic layer and an inelastic nonwoven layer in order to permanentlydeform the inelastic layer of the laminate and enable the elastic layerto extend and gather. The extent to which the nonwoven experiencespermanent damage instead of permanent deformation greatly depends on thetype of nonwoven present in the laminate and its ductility, i.e., itsability to sustain large strain deformation at high strain rates. Sinceit is most desirable for the nonwoven to retain as much of itsmechanical integrity during activation as possible, it is preferred touse nonwovens such as the new types of high-toughnessactivation-friendly spunbond nonwoven fabrics disclosed in a number ofpatents (U.S. Pat. No. 7,927,698, U.S. Pat. No. 7,781,527, and U.S. Pat.No. 7.960,478, by Autran, etc.), which also have been found to exhibitincreased post-activation strength and enhanced softness and loft.

In sum, current diaper chassis construction may include many componentsunder varying conditions. Adding to the complexity and costs, largeamounts of glue or adhesives are generally used in assembling thevarious components into a fully functional chassis. For example,adhesives may be used in the outer cover to attach the thin plastic filmused as a fluid barrier to the nonwoven fabric that provides acloth-like look and feel. Adhesives may be used in stretch elastic backears or side panels where the adhesively-bonded nonwoven shields againstthe tacky or blocky nature of the elastic film onto the body side whileagain providing a soft fabric feel. Or adhesives may be used in theconstruction of legband or waistband laminates where live stretch strandelastics are sandwiched in between two layers of inelastic nonwovensthat gather upon retraction. One difficulty of working with adhesives isachieving the balance between the right application level of adhesive toachieve adequate bond strength with cost and preventing processingissues such as adhesive burn-through with thin films or adhesivebleed-through with nonwovens. The latter can be particularly difficultas it often requires the use of thicker or more complex nonwovenstructures that can impose additional survivability issues duringactivation. Such fine-tuning of nonwoven/adhesive combinations to workproperly adds to the cost and complexity of the overall chassisconstruction. In addition, assembly of some components with adhesives,such as the legbands, waistbands, or stretch back ears, may occur at asite different from the location where the finished absorbent article ismade. Thus there is a continuing need for materials and methods ofchassis construction that can be cheaper and simpler.

One development to address these needs includes the use of polyolefinsas the materials of choice in the design of diaper chassis in theirentirety. These low cost resins can be successfully used for thecreation of most if not all chassis components described above,including adhesives. In addition, polyolefin-based assemblies have beenfound to be very amenable to alternative forms of bonding without needfor adhesive, such as ultrasonic bonding.

Another way to limit the need for adhesives can be use of an extrusionlamination process to construct bi- and tri-laminates (for example, seeUS publications 2009/0264844 and 2010/0040826, by Autran, etc.). Thiscan be done by bringing one or two layers of nonwovens onto a freshlyextruded and drawn-down film in close contact to each other at the nipof two compression rolls under controlled temperature and pressureconditions, forming a bond between the two layers by mechanicalinterlock of extruded film into the fibers of the nonwoven carrier web.It is also possible to apply a small amount of adhesive onto thenonwovens prior to combination with the extruded film, that is a loweramount than that which is typically used in adhesive laminatestructures, yet an amount that will still achieve the same level of bondstrength, in order to expand the range of bonding conditions. Engravedcompression rolls may be used to apply various pressure patterns ontothe laminate during its construction and introduce gradients in thedepth of nonwoven penetration into the film and therefore the amount ofbonding that is generated. The principles that guide the formulation ofskin layers in the films are a function of the nature of the nonwovenbeing unwound, especially with regard to its sheath composition, as theskin layer formulation should be thermally/physically/chemicallycompatible with the nonwoven in order to provide the most adequatebonding conditions and ensure sufficient bonding without compromisingthe structural and mechanical integrity of the laminate.

A variety of film structures have been created that provide a wide rangeof mechanical responses upon activation. This ranges fromhigh-performance elasticity with high recovery to plastoelasticity witha combination of permanent set and partial elastic recovery. The latterhave been referred to in the past as “plastoelastic” films, as theypossess some amount of permanent set as a result of a first drawingcycle (from the plastic component) and some amount of elastic recoveryobserved during subsequent cycles (elastic component). The relativeamount of each can be tailored to satisfy the need of any particulardesign that aims to provide conforming garments with superiorflexibility in their design, plus lower construction costs. Thisplastoelasticity is not strictly limited to films, as even nonwovenshave been formulated to possess this type of physical deformationbehavior.

Therefore, it is an object of the present invention to provide anabsorbent article chassis constructed only or predominantly with thinextrusion bilaminates, moving away from the current approach of handlingseparately backsheet and elastic films, elastic strands, and nonwovensand having to handle large amounts of adhesive, in multiple locations.One object of the present invention is to provide multilayer stretchlaminates that provide a finer distribution of the elastic and plasticcomponents in the stretch laminate structures. Another object is toprovide dual bilaminates, wherein two thin stretch film-basedbilaminates are brought together.

SUMMARY

One object of the present invention is to provide an absorbent articlecomprising a topsheet; an outer cover; at least one chassis component;and an absorbent core disposed between the topsheet and the outer cover,wherein at least one of the outer cover or chassis component comprises adual bilaminate comprising two bilaminates combined, wherein eachbilaminate comprises at least one nonwoven layer and at least onemultilayer film, and wherein the dual bilaminate has at most about 90grams per square meter basis weight.

Another object of the present invention is to provide an absorbentarticle comprising a chassis composite structure with a first and asecond bilaminate that have been laminated together by means ofadhesive, ultrasonic bonding, or other physical/chemical means, wherein40% or more of the longitudinal length of the waistband of the secondback waist region and/or 40% or more of the longitudinal length of thewaistband of the first front waist region of the article comprises atleast one of the bilaminate, wherein the bilaminate has at most about 60grams per square meter total basis weight or at most 45 grams per squaremeter total basis weight or at most 30 grams per square meter totalbasis weight.

It is a further object of the present invention to provide an absorbentarticle comprising a first and a second bilaminate that have beenlaminated together by means of adhesive, ultrasonic bonding, or otherphysical/chemical means, wherein the first bilaminate is plastoelasticand exhibits a percent recovery of strain (PRS) from about 10% to about95%, the second bilaminate is disposed on about 10% to about 100% of thearea of the first bilaminate and the second bilaminate has at least thesame or higher percent recovery of strain (PRS) as the first bilaminate,and wherein the combined bilaminate regions have at most about 90 gramsper square meter total basis weight, or at most about 80 grams persquare meter total basis weight, or at most about 70 grams per squaremeter total basis weight. It is a further object of the presentinvention to provide an absorbent article comprising a combinedbilaminate, wherein the polymeric material of the combined bilaminatescomprises at least 50% by weight of polyolefin, or at least 60% byweight of polyolefin, or at least 70% by weight of polyolefin, or atleast 80% by weight of polyolefin. A further object is to provide adisposable absorbent article comprising a pair of stretchable panels,for example back ear laminates of a taped diaper or the side panels of apant diaper, each stretchable panel comprising a first and a secondbilaminate that have been laminated together by means of adhesive,ultrasonic bonding, or other physical/chemical means, wherein eachstretchable panel has at most about 90 gsm total basis weight, or atmost about 80 grams per square meter total basis weight, or at mostabout 70 grams per square meter total basis weight and wherein thepolymeric material of the combined laminates comprises at least 50% byweight of polyolefin, or at least 60% by weight of polyolefin, or atleast 70% by weight of polyolefin, or at least 80% by weight ofpolyolefin.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentinvention will become better understood with regard to the followingdescription, appended claims, and accompanying drawings where:

FIGS. 1, 7, 8 and 9 are sectional side views of an extrusion bondedlaminates (EBL) useful in absorbent articles of the present invention.

FIG. 2 is a top plan view of an absorbent article including an EBL ofthe present invention.

FIG. 3 is a sectional side view of the absorbent article of FIG. 2.

FIG. 4 is a graph illustrating tensile properties of activatablenonwovens (three shown) useful in absorbent articles of the presentinvention versus a non-activatable nonwoven (one shown).

FIGS. 5A and 5B are graphs illustrating tensile properties of EBL usefulin absorbent articles of the present invention. From these graphs ModeII failure and peak force at break may be determined (see Tensile TestMethod).

FIGS. 6A, 6B, 6C, 10, 14 and 15 are sectional side views of multilayeredlaminates useful in absorbent articles of the present invention.

FIGS. 11, 12 and 13 are sectional side views of dual EBL useful inabsorbent articles of the present invention.

FIG. 16 is an SEM image of a five layer coextruded film of the presentinvention. While the specification concludes with claims particularlypointing out and distinctly claiming the subject matter that is regardedas the present invention, it is believed that the invention will be morefully understood from the following description taken in conjunctionwith the accompanying drawings. Some of the figures may have beensimplified by the omission of selected elements for the purpose of moreclearly showing other elements. Such omissions of elements in somefigures are not necessarily indicative of the presence or absence ofparticular elements in any of the exemplary embodiments, except as maybe explicitly delineated in the corresponding written description. Noneof the drawings are necessarily to scale.

DETAILED DESCRIPTION Definitions

“Absorbent article” refers to devices which absorb and contain bodyexudates and, more specifically, refers to devices which are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Exemplary absorbentarticles include diapers, training pants, pull-on pant-type diapers(i.e., a diaper having a pre-formed waist opening and leg openings suchas illustrated in U.S. Pat. No. 6,120,487), refastenable diapers orpant-type diapers, incontinence briefs and undergarments, diaper holdersand liners, feminine hygiene garments such as panty liners, absorbentinserts, breast pads and the like.

“Activatable nonwoven” refers specifically to nonwovens that havemechanical properties that interact well with films during theactivation process. Activatable nonwovens of the present invention givetensile curves (ASTM D882-02, gauge length=5 mm, specimen width=25.4 mm,crosshead speed=2.117 mm/s, deformation direction coinciding with thatapplied during the activation process) characterized by relatively lowmaximum forces and relatively large engineering strains. Specifically,if the nonwoven' s curve's maximum force point lies below 4 N/cm at anengineering strain value of greater than 100%, then, for the purposes ofthe present invention, it is deemed to be “activatable.” Examples ofthree activatable nonwovens and one non-activatable nonwoven are shownin FIG. 4. In FIG. 4, each curve's maximum force point is encircled.

“Activated” refers to a material which has been mechanically deformed soas to impart elasticity to at least a portion of the material, such as,for example by incremental stretching. As used herein the term“activation” means any process by which tensile strain produced byintermeshing teeth and grooves causes intermediate web sections tostretch or extend. Such processes have been found useful in theproduction of many articles including breathable films, stretchcomposites, apertured materials and textured materials. For nonwovenwebs, the stretching can cause fiber reorientation, change in fiberdenier and/or cross section, a reduction in basis weight, and/orcontrolled fiber destruction in the intermediate web sections. Forexample, a common activation method is the process known in the art asring rolling. U.S. Pat. Nos. 6,830,800, 5,143,679, and 5,167,897disclose examples of the activation process.

“Adhesive” refers to compositions comprising one or more thermoplasticpolymers, one or more tackifier resins, and typically a rheologymodifier or plasticizer. Adhesives contain 2% or more of a tackifierresin. An adhesive is generally used to join or bond two or morematerials together by applying it to at least one material and thenbringing it into contact with at least one other material withsufficient force and for a sufficient duration of time, that theadhesive can wet out or spread on each material to join them together(see definition of “tackifier” below).

“Adhesive-free” refers to a laminate where an adhesive is not used tobond the elastomeric member (e.g., elastomeric film) to the nonwoven ornonwovens, and therefore an adhesive is not part of the final laminatestructure.

“Adhesively bonded” or “adhesively laminated” refers to a laminatewherein an adhesive is used to bond an elastomeric member (e.g.,elastomeric film) to a nonwoven(s) or to a second elastomeric member.

“Bicomponent fiber” refers to fibers or filaments consisting of materialof two different compositions arranged across the cross-section of thefiber or filament. Each composition is typically delivered by a separateextruder to a spin pack designed to arrange the compositions intoarrangements such as sheath-core, side-by-side, segmented pie andislands-in-the-sea. The mutual arrangement of different compositions canbe beneficial in tailoring the chemical affinity between a film and anonwoven in a laminate.

“Bilaminate” refers to multilayer composite comprising a film (monolayeror multilayer) and one nonwoven, which is formed by extrusionlamination, adhesive lamination, sonic welding or pressure bonding.

“Blocking” refers to the phenomenon of a film sticking to itself or tothe opposite outer facing side of a composite laminate structure whenthe film or laminate is rolled, folded, or otherwise placed in intimatesurface to surface contact.

“Body-facing,” “inner-facing,” “outer-facing,” and “garment-facing”refer respectively to the relative location of an element or a surfaceof an element or group of elements. “Body-facing” and “inner-facing”imply the element or surface is nearer to the wearer's body during wear(i.e., closer to the wearer's body than a garment-facing surface or anouter-facing surface). “Garment-facing” and “outer-facing” imply theelement or surface is more remote from the wearer during wear (i.e.,element or surface is nearer to the wearer's garments that can be wornover the disposable absorbent article).

“Breathable” or “breathability” in reference to absorbent articles meansthat the absorbent article comprises a vapor-permeable layer orvapor-permeable multilayered structure that allows water vapor to passout of the interior of the diaper. The Water Vapor Transmission Rate(WVTR, reported in gm/m²/day), is a measure of breathability. WVTR ismeasured by the INDA/EDANA Worldwide

Strategic Partners WSP 70.4 (08) standard test method (see methods).

“Chemical affinity” refers to the nature of the chemical interactionbetween polymers. Two polymers are said to have a high degree ofchemical affinity if their enthalpy of mixing is close to zero.Conversely, polymers with large enthalpies of mixing (andcorrespondingly large differences in solubility parameter) have littlechemical affinity. (Solubility Parameters, section VII “Single-ValueSolubility Parameters of Polymers”, Polymer Handbook, 3rd Edition, 1989,J. Brandrup, E. H. Immergut, Ed. John Wiley & Sons, New York,Chichester, Brisbane, Toronto, Singapore). The following table shows theapproximate values for the difference in solubility parameter values fora polymer pair to be considered have “low”, “medium” or “high” chemicalaffinity:

Difference in Degree of Solubility Parameter Chemical Affinity(MPa{circumflex over ( )}0.5) low 2.5 or greater intermediate 1.5-2.49high   0-1.49

For example, polyethylene (“PE”) at 16.0 MPâ0.5 and polypropylene (“PP”)at 18.8 MPâ0.5 have a difference of 2.8 MPâ0.5 and therefore exhibit alow degree of chemical affinity. The method use to determine thesolubility parameter of a polymer is described by Robert Hayes in the“Journal of Applied Polymer Science,” volume 5, pages 318-321, 1961.

“Coextrusion” refers to a process of making multilayer polymer films.When a multilayer polymer film is made by a coextrusion process, eachpolymer or polymer blend comprising a layer of the film is melted byitself. The molten polymers may be layered inside the extrusion die, andthe layers of molten polymer films are extruded from the die essentiallysimultaneously. In coextruded polymer films, the individual layers ofthe film are bonded together but remain essentially unmixed and distinctas layers within the film. This is contrasted with blendedmulticomponent films, where the polymer components are mixed to make anessentially homogeneous blend or heterogeneous mixture of polymers thatare extruded in a single layer.

“Compositionally identical” refers to compositions that have such closeresemblance as to be essentially the same (e.g., two layers of amulti-layer film having nominally the same ingredients in the sameproportions (such as the A layers in an ABA co-extruded film)).

“Comprise,” “comprising,” and “comprises” are open ended terms, eachspecifies the presence of what follows, e.g., a component, but does notpreclude the presence of other features, e.g., elements, steps,components known in the art, or disclosed herein.

“Consisting essentially of” is used herein to limit the scope of subjectmatter, such as that in a claim, to the specified materials or steps andthose that do not materially affect the basic and novel characteristicsof the subject matter.

“Crystallization rate” refers to the kinetics of crystal nucleation andgrowth from a polymer melt, as it is cooled in, and following, anextrusion lamination process. Crystallization rate reflects the route bywhich a polymer solidifies from a molten, amorphous state. DifferentialScanning calorimetry (DSC) may be used according to ASTM D 3418 asdescribed in more detail in the Test Methods to determinecrystallization rates of polymers, polymer blends, and formulationscomprising polymers useful in films, including skin and tie layers, ofthe present invention.

As used herein “depth of engagement” (DOE) means the extent to whichintermeshing teeth and grooves of opposing activation members extendinto one another.

“Diaper” refers to an absorbent article generally worn by infants andincontinent persons about the lower torso so as to encircle the waistand legs of the wearer and that is specifically adapted to receive andcontain urinary and fecal waste. As used herein, term “diaper” alsoincludes “pants” which is defined below.

“Disposable” in reference to absorbent articles, means that theabsorbent articles are generally not intended to be laundered orotherwise restored or reused as absorbent articles (i.e., they areintended to be discarded after a single use and may be recycled,composted or otherwise discarded in an environmentally compatiblemanner).

“Disposed” refers to an element being positioned in a particular placewith regard to another element. When one group of fibers is disposed ona second group of fibers, the first and second groups of fibersgenerally form a layered, laminate structure in which at least somefibers from the first and second groups are in contact with each other.In some embodiments, individual fibers from the first and/or secondgroup at the interface between the two groups can be dispersed among thefibers of the adjacent group, thereby forming an at least partiallyintermingled, entangled fibrous region between the two groups. When apolymeric layer (for example a film), is disposed on a surface (forexample a group or layer of fibers), the polymeric layer can belaminated to or printed on the surface.

As used herein, the terms “elastic,” “elastomer,” and “elastomeric”refer to any material which generally is able to, upon application of atensile force, extend to an engineering strain of at least 50% withoutbreaking or rupturing, and is able to recover substantially to itsoriginal dimensions after the deforming force has been removed.

“Engineering strain” is the change in length of a specimen (in thedirection of applied stress or strain) divided by the specimen'soriginal length (William D. Callister Jr., “Materials Science andEngineering: An Introduction”, 1985, John Wiley & Sons, Inc. New York,Chichester, Brisbane, Toronto, Singapore). To calculate percentengineering strain, the engineering strain is multiplied by 100.

“Ethylene rich” refers to the composition of a polymeric layer (e.g., asheath of a bicomponent fiber or a skin layer of a film) or a portion ofa layer of an EBL or nonwoven that comprises at least about 80% byweight of polyethylene (including homopolymers and co-polymers). Forexample, a sheath of a core-sheath bicomponent fiber, wherein the sheathis comprised of greater than about 80% by weight of a linear, lowdensity polyethylene, is ethylene rich.

“Extensible”, “plastic” and “extendibility” (e.g. extensible nonwoven,plastic film or extendibility of the elastomer), means that uponapplication of a tensile force, the width or length of the material inthe relaxed position can be extended or increased, without rupture orbreakage. Further, upon release of the applied force, the material showslittle recovery, for example, the percent recovery of strain, PRS (asmeasured by the Percent Strain Recovery Test, PSRT, a modifiedhysteresis method; see test methods) is less than 80%, or PRS is lessthan 50%, or PRS is less than 25%, or PRS is less than 10%. It should benoted that the percent recovery of strain (PRS) is equivalent to thepercent strain recovery.

“Extrusion bonded laminate (‘EBL’)” refers to a multilayer compositeformed by extruding an elastomeric extrudate directly onto at least onenonwoven at or near a nip formed between two calender rollers, such thatat least some nonwoven fibers penetrate into the soft extrudate film inorder to join the film and the nonwoven. The amount of penetration ofnonwoven into the soft extrudate may be controlled by selecting a nipgap smaller than the caliper of the nonwoven plus the film, by adjustingthe pressure of the rolls, or by other means well understood to one ofordinary skill in the art. In one embodiment, the elastomeric extrudatemay be a monolayer film comprising one or more elastomeric polymers. Inanother embodiment, the elastomeric extrudate may be a coextrudedmultilayer film with one or more outer layers and one or more innerlayers.

“Extrusion lamination” or “extrusion coating” refers to processes bywhich a film of molten polymer is extruded onto a solid substrate (e.g.,a nonwoven), in order to coat the substrate with the molten polymer filmto bond the substrate and film together.

“Joined” refers to configurations whereby an element is directly securedto another element by affixing the element directly to the other elementand to configurations whereby an element is indirectly secured toanother element by affixing the element to intermediate member(s) whichin turn are affixed to the other element. Materials may be joined by oneor more bonding processes including adhesive bonding, thermal welding,solvent welding, ultrasonic bonding, extrusion bonding, and combinationsthereof.

“Laminate” means two or more materials that are bonded to one another bymethods known in the art, e.g., adhesive bonding, thermal bonding,ultrasonic bonding.

“Liquid-permeable” (or “liquid-pervious”) and “liquid-impermeable” (or“liquid-impervious”) refer to the penetrability of materials in thecontext of the intended usage of disposable absorbent articles.Specifically, “liquid permeable” refers to a layer or a layeredstructure having pores, openings, and/or interconnected void spaces thatpermit liquid water to pass through its thickness at less than 5 mbar ofhydrostatic head (as defined by INDA 80.6-01). Conversely, “liquidimpermeable” refers to a layer or a layered structure through thethickness of which liquid water cannot pass through its thickness atless than 5 mbar of hydrostatic head (as defined by INDA 80.6-01). Alayer or a layered structure that is water-impermeable according to thisdefinition may be vapor-permeable, for example permitting transmissionof air and water vapor. Such a vapor-permeable layer or layeredstructure is commonly known in the art as “breathable.”

“Machine direction” (also “MD” or “length direction”) as applied to afilm or nonwoven material, refers to the direction that was parallel tothe direction of travel of the film or nonwoven as it was processed inthe forming apparatus. The “cross machine direction” (also “CD” or“width direction”) refers to the direction perpendicular to the machinedirection.

“Non-adhesively joined” refers to joining two or more materials withoutuse of an adhesive. Non-limiting examples of non-adhesively joinedmaterials include extrusion coating of a web, sonic welding of two ormore webs, pressure bonding of at least one film and one or morenonwovens, etc.

“Outer cover” refers to that portion of the diaper which is disposedadjacent to the garment-facing surface of the absorbent core. Outercovers have tensile properties that enable ease of the application ofthe article, as well as enabling the article to conform to the wearer'sbody. In some embodiments it may prevent the excreta and/or exudatescontained therein from soiling garments or other articles which maycontact the diaper, such as bedsheets and clothing. In theseembodiments, the outer cover may be impervious to liquids. In otherembodiments, the outer cover may be liquid pervious. Outer covers of thepresent invention may be breathable. Outer covers of the presentinvention may comprise a multilayer laminate structure, including anEBL.

“Pant,” “training pant,” “pre-closed diaper,” “pre-fastened diaper,”“pull-on diaper,” and “pant-like garment” as used herein, refer todisposable garments having a waist opening and leg openings designed forinfant, children, or adult wearers. A pant can be configured such thatthe pant has a closed waist and leg openings prior to being donned onthe wearer, or the pant can be configured such that the waist is closedand the leg openings formed while being donned on the wearer. A pant maybe preformed by any suitable technique including, but not limited to,joining together portions of the article using refastenable and/ornon-refastenable bonds (e.g., seam, weld, adhesive, cohesive bond,fastener, etc.). A pant may be preformed anywhere along thecircumference of the article (e.g., side fastened, front waist fastened,rear waist fastened). Examples of suitable pants are disclosed in U.S.Pat. No. 5,246,433; U.S. Pat. No. 5,569,234; U.S. Pat. No. 6,120,487;U.S. Pat. No. 6,120,489; U.S. Pat. No. 4,940,464; U.S. Pat. No.5,092,861; U.S. Pat. No. 5,897,545; U.S. Pat. No. 5,957,908; and U.S.Patent Publication No. 2003/0233082 A1.

“Permanent set” is the permanent deformation of a material after removalof an applied load.

In the case of elastomeric films, permanent set is the increase inlength of a sample of a film after the film has been stretched to agiven length and then allowed to relax as described in the Two CycleHysteresis Test. Permanent set is typically expressed as a percentincrease relative to the original size.

“Petrochemical” refers to an organic compound derived from petroleum,natural gas, or coal.

“Petroleum” refers to crude oil and its components of paraffinic,cycloparaffinic, and aromatic hydrocarbons. Crude oil may be obtainedfrom tar sands, bitumen fields, and oil shale.

“Plastoelastic” and “elastoplastic” as used herein are synonymous andrefer to any material that has the ability to stretch in a substantiallyplastic manner during an initial strain cycle (i.e., applying a tensileforce to induce strain in the material, then removing the force allowingthe material to relax), yet which exhibits substantially elasticbehavior and recovery during subsequent strain cycles. Plastoelasticmaterials contain at least one plastic component and at least oneelastic component, which components can be in the form of polymericfibers, polymeric layers, and/or polymeric mixtures (including, forexample, bi-component fibers and polymeric blends including the plasticand elastic components). Suitable plastoelastic materials and propertiesare described in U.S. 2005/0215963 and U.S. 2005/0215964.

“Post activation set” is the permanent set of an elastic material whichhas undergone only the stretching associated with activation. The postactivation set (PAS) of a material is measured by marking the materialbefore activation with two pen marks separated by a known distance (L₁)in the direction of activation. The material is then activated, and thedistance between the two marks is measured again (L₂). The postactivation set, as a percent, is calculated by the equation:

PAS (%)=[(L ₂ −L ₁)/L ₁]×100

“Propylene rich” refers to the composition of a polymeric layer (e.g., asheath of a bicomponent fiber or a skin layer of a film) or a portion ofa layer of an EBL or nonwoven that comprises at least about 80% byweight of polypropylene (including homopolymers and copolymers). Forexample, a tie layer comprising 96% VISTAMAXX 6102 (16% by weight PE/84%by weight PP), is propylene rich.

“Renewable resource” refers to a natural resource that can bereplenished within a 100 year time frame. The resource may bereplenished naturally, or via agricultural techniques. Renewableresources include plants, animals, fish, bacteria, fungi, and forestryproducts. They may be naturally occurring, hybrids, or geneticallyengineered organisms. Natural resources such as crude oil, coal, andpeat which take longer than 100 years to form are not considered to berenewable resources.

“Side panel,” “front ear,” “back ear,” or “ear panel” refers to thatportion of an absorbent article which may be a chassis component andthat is disposed adjacent to or next to the outer cover or core ortopsheet and connect a front waist edge to a back waist edge. Sidepanels or front/back ears have tensile properties that enable ease ofthe application of the article, as well as enabling the article toconform to the wearer's body. Side panels or front/back ears of thepresent invention may comprise a multilayer laminate, including an EBL.Examples of side panels that may be used in the present invention aredescribed and illustrated in EP 1150833 (referenced as ear panels).

“Skin layer” refers to an outer layer of a coextruded, multilayer filmthat acts as an outer surface of the film during its production andsubsequent processing.

“Synthetic polymer” refers to a polymer which is produced from at leastone monomer by a chemical process. A synthetic polymer is not produceddirectly by a living organism.

“Tackifier” refers to an adhesive component with a glass transitiontemperature in the range from about 70° C. to about 150° C. thatdecreases the melt viscosity of a rubbery polymer and increases therubbery polymer's glass transition temperature and decreases the rubberypolymer's entanglement density.

“Tie layer” refers to a layer of a coextruded, multilayer film that actsas an intermediary between an inner layer of the film and anothermaterial, such that the laminate strength between the inner layer andthe other material is improved (increased or decreased). The tie layer'scomposition can be adjusted to modify or optimize the chemical andphysical interactions between film and nonwoven. Tie layers of thepresent invention do not contain more than 2% of a tackifier resin, andare substantially continuous over the entire surface of the coextrudedfilm. In the present invention, it may be desirable to have a tie layerand skin layer which are compositionally identical.

“Web” means a material capable of being wound into a roll. Webs may befilms, nonwovens, laminates, apertured laminates, etc. The face of a webrefers to one of its two dimensional surfaces, as opposed to its edge.

“X-Y plane” means the plane defined by the MD and CD of a moving web orthe length.

Multilayered Stretch Films and Dual Bilaminates

The present invention provides multilayered films and bilaminates formedthrough the use of extrusion lamination. The present invention relatesto structures disclosed in US publications 2009/0264844 and2010/0040826, by Autran, etc.. The present inventors have discoveredthat varying the number and types of layers, for example, by sublayeringthe films with thinner layers, or using an increased number of internallayers, can offer surprising property benefits. For instance, multilayerlaminates of the present invention may exhibit improved toughness asdemonstrated by improved puncture resistance during activation. Themultilayered film composition allows for improved film processability,and allows for opportunities for higher line speeds and lower film basisweights. Without being bound by theory, it is thought that thinnerlayers reduce the risk and the occurrence of micro-hole formation duringactivation. As the thickness of the sublayers decrease, there is lessspace for the holes to form and for stresses to concentrate, reducingthe risk of catastrophic failure during activation or use as taught byprinciples of fracture mechanics. The use of stress-diffusive sublayersmade of flexible, ductile, and energy-absorbing material can improve theoverall mechanical energy of the stretch laminate.

A specific type of multilayer lamination, the dual bilaminates of thepresent invention, is designed by bringing two thin film-basedbilaminates together, hence the terminology of dual bilaminates. Themultilayer structure may be such that two multilayer films arethemselves layered and bonded together with adhesive, thus creating adual bilaminate. That is, the additional polymeric layer that isincorporated into the multilayer structure may be an adhesive. The twocombined multilayer films may be the same or may be different. Further,the additional polymeric layer may be between the outer layers of thetwo combined multilayer films. Specifically, two bilaminates, comprisinga nonwoven and a multilayer co-extruded film, may be layered and bondedtogether at the bilaminate outer layer film interface with an adhesivelayer. Further, the nonwoven of a bilaminate may be bonded to themultilayer film by an adhesive lamination process or by an extrusionlamination process. In some embodiments of the present invention, thetwo bilaminates comprise a three layer co-extruded film (A1BA2) that areextrusion laminated to a nonwoven (depicted in FIG. 7), where the “A1”tie layer and the “A2” skin layer are the plastoelastic outer layers,the “B” layer is the inner elastomeric layer, and the combination of thetwo bilaminates with an adhesive layer, C1, creates a multi-layeredstructure NW-A₁B₁A₂C₁A₃B₂A₄-NW as depicted in FIG. 11. In someembodiments of the present invention, the multilayer structure maycomprise two bilaminates with five layer co-extruded films (ABCBA),where “A” are plastoelastic outer layers, “B” are the inner elastomericlayers, C₁ and C₃ are additional polymeric layers, and combination ofthe two bilaminates with an adhesive layer, C₂, creates themulti-layered structure NW-A₁B₁C₁B₂A₂C₂A₃B₃C₃B₄A₄-NW, as depicted inFIG. 12.

In some embodiments of the present invention, the bilaminates maycomprise a three layer co-extruded film (ABA), and a 5 layer co-extrudedfilm (ABCBA), where “A” are plastoelastic outer layers, “B” are theinner elastomeric layers, C is an additional polymeric layer andcombination of the two bilaminates with an adhesive layer, C₂, creates amulti-layered structure NW-A₁B₁C₁B₂A₂C₂A₃B₃A₄-NW as depicted in FIG. 13.

Current stretch laminates are typically constructed in separate steps byfirst extruding an elastic film before adhesively bonding it to twononwovens and taking it through an activation process. This generallyplaces constraints on the film design in not only requiring the film tohave enough mass to be stably extruded and wound by itself, but also inrequiring the plastic skin layers to be coextruded or some type ofsurface treatment to be applied to prevent the film from sticking duringits production or from being rolled onto itself. Nonwovens currentlyused in commercial applications are carded or standard spunbond websthat require large amounts of glue for the nonwoven to remain attachedto the film and prevent flocks of broken fibers from getting loose afterthe deep activation that typically produces significant damage to thewebs.

The present invention offers an alternative approach to createmultilayer laminates with a number of previously unsuspected benefits.These new dual bilaminates are designed to bring two thin stretchfilm-based bilaminates together. Only a minimal amount of adhesive isnecessary to bond the film surfaces of the two bilaminates, as films areinherently more readily bondable than nonwovens; and this offerssignificant savings. Alternatively, the two bilaminates can be combinedvia point melting through a hot pin aperturing process, ultrasonicbonding, pressure bonding, or chemical/thermal bonding, hence forsakingthe use of adhesive.

Each bilaminate may have a total basis weight ranging from about 20 gsmto about 55 gsm, with the film ranging from about 10 gsm to about 30gsm, and the nonwoven between about 10 gsm to about 25 gsm. The twobilaminates may be brought into contact on their film faces, the totalbasis weight of the dual bilaminate ranging from about 40 to about 110gsm.

In one embodiment, the same two thin elastomeric bilaminates are used toachieve a high-performing dual bilaminate with better mechanicalintegrity than a trilaminate of equal basis weight made of a single filmtwice as thick. This approach may be used, for example, to createlow-cost stretch dual bilaminates with performance similar to thosecurrently used in absorbent products. One option to create the finaldual bilaminate is for the bilaminate to be folded onto itself.

The dual bilaminates may be constructed with either the same bilaminate,or two different bilaminates made of different films and or nonwovens.The bilaminates used are preferably the extrusion type, detailed below,where process simplification and cost savings are derived both from theelimination of adhesive and the ability to use lower basis weightspunbond nonwovens. The same conceptual approach could be replicatedwith bilaminates made by adhesive lamination, as opposed to extrusionlamination, though the cost structure would make them less attractivedue to the presence of adhesive. The dual bilaminates have a largernumber of film layers than the previously disclosed trilaminatestructures with coextruded 3 layer films comprising an elastomeric coreand two thin facing layers based on polyethylene-rich formulations thatare capable of acting as a tie-layer on the nonwoven side and a skinlayer on the open side. For example, the dual bilaminates of the presentinvention may have combined multilayer films with 6, 8, 10 or morelayers plus at least one additional low level adhesive layer, as shownin FIGS. 11, 13 and 12, respectively.

The benefits of using bilaminates to create all or most diaper chassiscomponents include the reduction in complexity, the surprising boost intoughness and the opportunity to minimize the use of adhesives and allthe issues that come with them (complexity, consistency/supply issues,glue bleed through, and odor).

One benefit of the dual bilaminates of the present invention is that thedual bilaminates show improved puncture resistance during activation,which can translate into either deeper depth of engagement's (DOE's)which creates a stretch laminate with lower permanent set and higherachievable stretch, or the ability to further down-gauge the film toachieve cost-savings. The more activation-friendly the extensible (bico)spunbond nonwoven is, the further the limits of activation andsurvivability can be pushed at a lower film gauge. Another benefit isthat the more and/or thicker the plastic layers, the more there can be atailored plastoelastic response of the film to mechanical activation.Another benefit is that dual bilaminates can provide an opportunity forimprovement in film processability, with higher line speed and lowerfilm basis weights. In extrusion lamination, the nonwoven is a carrierweb for the process, which enables production of bilaminates with verylow film basis weights. There is also the possibility that with theaddition of a third extruder, the trim or edges of the laminate can berecycled into an additional polymeric layer within the multilayer filmstructure, without detrimental change in the properties. With a thirdextruder, it may also be possible to recycle trim blended with a plasticadditive into an additional polymeric layer within the multilayer filmstructure to provide a material with plastoelastic properties. There isalso the possibility that with the addition of a third extruder amultilayer film structure can be produced comprising an additionalpolymeric layer with a high performance elastomer, for example SBC. Orone could incorporate a lower-cost filled layer to reduce the overallcost of the film. A right combination of filled and unfilled layers mayproduce micro-pores across the thickness of the film and thus introducebreathability. The preferred range of WVTR for an outer cover comprisinga multilayer laminate ranges from about 500 gm/m²/day to about 15,000gm/m²/day. It is known in film technology that one way to avoid pinholesin stretched materials is to bond two separately stretched layerstogether. If the individually stretched layers develop pinholes, it isunlikely that pinholes in both layers will align to create a hole thatgoes through both layers. In microporous breathable film technology, thestretching that creates micropores in the film can also generatepinholes that can allow liquids to leak through the film. However, bybonding two layers of microporous film together, there is very littlechance that a pinhole in each layer will occur in the same area of thebonded double-layer film. Hence, there is little chance that such abonded double-layer film will leak. This is not because there are nopinholes in the individual films, though; instead, it is becauseexisting pinholes do not align in the final bonded film. The samebenefit occurs when the bonded dual bilaminate structure is stretched ormechanically activated.

Without being bound by theory, it is believed that the thinner layersreduce the risk and the occurrence of micro-hole formation duringactivation, which when present can result into catastrophic failureduring activation or during use. This is a scale effect benefit thatbecomes even more prominent as the thickness of the sub-layers decreases(less space for the holes to form and for stresses to concentrate). Thatis, the closer the layers get to a micron scale, the greater thebenefit. The introduction of stress-diffusive sub-layers made offlexible, ductile, and energy-absorbing material can be readilyenvisioned as means of improving the overall mechanical integrity of thestretch laminate. The skin-layer formulation falls into that category.The issue of dramatic tear growth in the film may be further impeded bythe presence of a continuous filament spunbond nonwoven closely bondedto the film, assuming that the nonwoven itself survives the activationand experiences only minimal damage.

In general, referring to FIG. 7, an extrusion bonded laminate mayinclude at least one nonwoven (NW1) (which may have multiple layers,e.g., SSS, SMS, SSMMS, SSM, etc.) joined to an elastomeric film (whichmay comprise multiple film layers (e.g., A1, B, and A2), where A1 and A2are outer layers and B is an inner layer of the multilayer film. In someembodiments of the present invention, the inner layer B in FIG. 7, maybe split. The multilayer film may comprise at least two inner layerscomprising one or more elastomeric components, at least one outer layercomprising a plastoelastic component, and at least one additionalpolymeric layer that is disposed between at least two inner layers. Inother embodiments, the multilayer film may comprise at least one innerlayer comprising one or more elastomeric components, at least two outerlayers comprising a plastoelastic component, and at least one additionalpolymeric layer that is disposed between at least two layers thatcomprise one or more elastomeric components.

For example, in the bilaminate shown in FIG. 7, the B layer may be splitinto layers labeled B1/C1/B2 to form a bilaminate with a 5 layer filmshown in FIG. 8. Layers B1 and B2 are inner layers of the multilayerfilm, layers A1 and A2 are outer layers of the multilayer film, and C1is an additional polymeric layer that is between two of the inner layersof the multilayer film. Layers A1/B1/C1/B2/A2 together may be consideredthe multilayer film. The laminate shown in FIG. 1 , with two nonwovens,is a laminate with improved strength and toughness. Adhesive(s) may ormay not be used to bond the nonwoven(s) to the multilayer film, or theymay be bonded via the extrusion lamination process.

The elastomeric component of one or more inner layers of the multilayerfilm may be a copolymer of polypropylene and polyethylene, may be astyrenic block copolymer, may comprise stacked layers of a copolymer ofpolypropylene and polyethylene and a styrenic block copolymer, or maycomprise blends of a copolymer of polypropylene and polyethylene and astyrenic block copolymer. The inner layer may comprise multiplesublayers, wherein the thickness of each sublayer is less than about 1micron. In some embodiments, the inner layer may further comprise afiller.

In some embodiments, any outer layer may comprise polyethylene, may be alow density polyethylene, or may be a linear low density polyethylene,or may be a blend of a elastomeric polyethylene and a plasticpolyethylene. In some embodiments, an outer layer may comprise a blendof a elastomeric and/or plastic polyethylene and an olefinic blockcopolymer (for example, Infuse 9107, manufactured by Dow). In someembodiments, any outer layer may comprise ethylene rich copolymers (forexample, ethane-1-octene copolymers), wherein the ethylene content is10% to 97%. In some embodiments, any outer layer may comprise a blend ofInfuse 9107 and Elite 5800 or Elite 5815, manufactured by Dow.

In some embodiments, the additional polymeric layer may split an innerlayer into two parts. In some embodiments, the additional polymericlayer may split each inner layer into two parts. In some embodiments, atleast one additional polymeric layer is intercalated, or disposedbetween, at least two different inner layers. In some embodiments, theadditional polymeric layer may be produced via a extrusion laminationprocess. In some embodiments, the additional polymeric layer maycomprise a plastoelastic component. In some embodiments, the additionalpolymeric layer may be recycled trim (film only, nonwoven only, or filmand nonwoven). In some embodiments, the additional polymeric layer maybe a nonwoven with a meltblown layer comprising at least one elastomericcomponent.

In some embodiments, the polymeric layer, C, may be from about 5 gsm toabout 26 gsm, or may be from about 10% to about 65% of the total filmbasis weight. In some embodiments, the polymeric layer, C, may be fromabout 5 gsm to about 10 gsm, or may be from about 10% to about 40% ofthe total film basis weight. In some embodiments, at least one of thepolymeric layers, C, may be from about 1 gsm to about 10 gsm, or may befrom about 2% to about 40% of the total film basis weight. In someembodiments, the additional polymeric layer, C, may be the same materialas A1 or as A2 (the outer layer).

In some embodiments, such as one dual bilaminate embodiment, the atleast one additional polymeric layer may comprise or be an adhesive, forexample, a styrenic block copolymer adhesive or a polyolefin-basedadhesive.

Another example of a dual bilaminate is illustrated in FIG. 11, wheretwo multilayer film bilaminates are bonded together by an additionalpolymeric layer, C1. The multilayer film structure may be consideredA1/B1/A2/C1/A3/B2/A4. In some embodiments, the additional polymericlayer, a C layer, may be an adhesive.

The benefits of the present multilayer laminates may be extended withfurther splitting of layers. For example, in FIG. 12, each B layer ofFIG. 11 may be split and have its own additional polymeric layer placedin between. In some embodiments, any additional polymeric layer, a Clayer, may be an adhesive. In some embodiments, only C2 may be anadhesive. In some embodiments (FIG. 10), an adhesive layer is split intotwo and an additional polymer layer (for example C2), which may be aplastoelastic-based film, a polyolefin-based film, or an elastomericfilm, is inserted between the two layers of adhesive.

In some embodiments, the multilayer structure may be activated in eitherthe machine direction, the cross direction, or both directions. In someembodiments, the activated multilayer structure may possess elasticrecoverability from about 10% to about 95% of its original dimension.

One embodiment involves the use of bilaminates that include films ofthree-layer, five-layer, or multi-layered coextruded layers. Theselection of resins, nonwovens, and constructions must be considered.All major classes of adhesives can be used to bond the two stretchbilaminates together, though polyolefin-based ones may have betterintrinsic compatibility with the other components of the system. Thedual bilaminate is then subjected to mechanical activation to releasethe stretch.

Another embodiment envisions the possibility of pre-straining one of thebilaminates prior to combining it to the other bilaminate and activatingthe assembly again, in the same direction. The combination may be doneafter allowing the pre-strained one to either fully or partially relax.It may also be done with the pre-strained layer being held in fullextension during the lamination process. The latter scenario would buildhigh recovery. In this way, the stretch response of the dual bilaminatemay be tailored, as the two layers will respond differently tosubsequent loading.

One of the novel features of the bilaminates of the present invention isthe use in the absorbent article chassis of extensible nonwovens capableof sustaining large scale plastic deformation at high strain rateswithout undergoing significant damage. The result is activated laminatesthat can derive a major portion of their strength from the nonwoven. Bynot having to rely on the film to provide strength, one can use lowercost films, thus offering an overall lower cost while still achievingthe strength required in any part of the chassis. Such nonwovens areidentified by a survivability criteria determined by testing them in ahigh-speed activation press. The tensile strength of the nonwoven iscompared before and after high-speed activation. The survivabilitycriteria which defines the most preferred extensible nonwoven is whetherthe tensile strength of the activated nonwoven, after activation at thetarget engineering strain needed for the particular application, is notsignificantly lower than the tensile strength of the non-activatednonwoven. For example, the nonwoven is activated on the High SpeedResearch Press, HSRP, to about 245% engineering strain with a pair offlat plates with intermeshing teeth having a depth of engagement ofabout 4.06 mm and a pitch of about 2.49 mm. Extensible nonwovens usefulfor bilaminates of the present invention retain at least about 30% ofthe tensile strength after activation, or retain greater than about 60%of the tensile strength after activation, or retain greater than about80% of the tensile strength after activation, or may retain about 100%of the tensile strength after activation. U.S. Pat. Nos. 7,776,771 and7,491,770 by Autran disclose additional examples of extensible nonwovensuseful for the present invention.

Beyond the parameters illustrated in Tables 4 and 6, laminates useful inabsorbent article of the present invention may have parameters asdisclosed in the following paragraphs.

Laminates useful in absorbent article of the present invention may havea blocking force of less than about 0.4 N/cm, about 0.24 N/cm, or about0.12 N/cm.

Laminates useful in absorbent article of the present invention may havea basis weight of from about 10 gsm to about 135 gsm, from about 20 gsmto about 100 gsm, from about 40 gsm to about 80 gsm, or from about 50gsm to about 60 gsm.

Laminates useful in absorbent article of the present invention may havelaminate bond strength from about 0.5 to about 3.5 N/cm or from about 1to about 2 N/cm (see Tensile Test (Mode II)). Laminates useful inabsorbent article of the present invention may have laminate bondstrength from about 0.5 to about 2 N/cm (see T-Peel Test (Mode I)).

Laminates useful in absorbent article of the present invention may havean ultimate tensile strength of greater than about 2 N/cm, or greaterthan about 3 N/cm or greater than about 4 N/cm (see Tensile Test (ModeII)).

Laminates useful in absorbent article of the present invention may befree from pinholes.

Laminates useful in absorbent article of the present invention may havea percent engineering strain at break from about 100% to about 700%,from about 120% to about 450%, or from about 50% to about 300%.

Laminates useful in absorbent article of the present invention, as wellas the components that comprise them (e.g., an outer cover, a back orfront ear, a side panel) may be elastic to at least about 50%, about70%, about 100%, about 130%, about 175%, or about 250% engineeringstrain. Laminates useful in absorbent article of the present inventionmay have a percent set less than about 10%, force relaxation less thanabout 40%, and a Cycle 1 unload force at 50% strain of greater thanabout 0.10 N/cm as measured by the two cycle hysteresis test. In someembodiments, the percent set of the laminate may be about 20% or less,about 15% or less, or about 10% or less as measured by the two cyclehysteresis test having a 70% strain first loading cycle and a 70% strainsecond loading cycle. In other embodiments, the percent set of thelaminate may be about 20% or less, about 15% or less, or about 10% orless, the force relaxation less than about 40%, and a Cycle 1 unloadforce at 50% strain of greater than about 0.10 N/cm or greater thanabout 0.05 N/cm as measured by the two cycle hysteresis test having a130% strain first loading cycle and a 130% strain second loading cycle.In some embodiments, the percent set of the laminate may be about 20% orless, about 15% or less, or about 10% or less, force relaxation lessthan about 40%, and a Cycle 1 unload force at 50% strain of greater thanabout 0.10 N/cm or greater than about 0.05 N/cm as measured by the twocycle hysteresis test having a 165% strain first loading cycle and a165% strain second loading cycle. In some embodiments, the percent setof the laminate may be about 20% or less, about 15% or less, or about10% or less, force relaxation less than about 40%, and a Cycle 1 unloadforce at 50% strain of greater than about 0.10 N/cm or greater thanabout 0.05 N/cm as measured by the two cycle hysteresis test having a200% strain first loading cycle and a 200% strain second loading cycle.In some embodiments, the laminate hysteresis forces are measured atelevated temperatures (for example at 34 degrees or 38 degrees Celsius,to simulate wearing conditions of an absorbent article) using the twocycle hysteresis test having a first loading cycle and a second loadingcycle with a maximum of 100% strain, or 130% strain, or 165% strain, oreven 200% strain. The laminate may have a Cycle 1 unload force at 50%strain of greater than about 0.10 N/cm or greater than about 0.05 N/cm,or greater than about 0.02 N/cm, as measured by the two cycle hysteresistest at a temperature of about 34 degrees Celsius, or about 38 degreesCelsius, and having a first loading cycle and a second loading cyclewith a maximum strain of 100% strain, or 130% strain, or 165% strain, oreven 200% strain.

The multilayer laminates of the present invention may be activated inthe machine direction (MD) and/or the cross direction (CD), and have alevel of stretch (% engineering strain at 1 N/cm force, as measured bythe tensile test) from at least 10% strain to about 300% strain, or atleast 50% strain to about 250% strain, or at least 75% to about 175%strain. In some embodiments, the laminate may be activated using agradient DOE (deeper in some areas than others) to create a stretchlaminate having areas with a high level of stretch and other areas withlower levels of stretch.

In some embodiments, a laminate or multilayer film may be activated andpossess a percent recovery of strain (PRS) from about 10% to about 95%.In some embodiments, a laminate or multilayer film may be activated andthen have a permanent deformation (post-activation set) from about 5% toabout 90%. In some embodiments, a multilayer film may be activated,wherein the tensile strength of the activated multilayer film is atleast about 30% to about 100% of the tensile strength of the multilayerfilm prior to activation. In some embodiments, a laminate may beactivated, wherein the tensile strength of the activated laminate is atleast about 30% to about 100% of the tensile strength of the laminateprior to activation.

Multilayer films and laminates of the present invention may bemechanically activated by one or a combination of activating means,including, activating the web through intermeshing gears or plates,activating the web through incremental stretching, activating the web byring rolling, activating the web by tenter frame stretching, andactivating the web in the machine direction between nips or roll stacksoperating at different speeds. Incremental stretching rollers may beused to activate multilayer films and laminates in the MD, CD, at anangle, or any combination thereof. The depth of engagement used forincremental stretching can be, for example, from about 0.05 inches toabout 0.40, from about 0.10 inches to about 0.30 inches, or about 0.16inches to about 0.25 inches. In some embodiments, the depth ofengagement used for incremental stretching is about 0.05 inches, about0.10 inches, about 0.15 inches, about 0.20 inches, about 0.25 inches,about 0.30 inches, about 0.35 inches, or about 0.40 inches. The depth ofengagement can be, for example, at least about 0.05 inches or at leastabout 0.10 inches. The depth of engagement can be, for example, no morethan about 0.10 inches, no more than about 0.18 inches, no more thanabout 0.25 inches, no more than about 0.30 inches, no more than about0.35 inches, or no more than about 0.40 inches. The pitch of engagementcan be, for example, from about 0.060 inches to about 0.200 inches, fromabout 0.080 inches to about 0.150 inches, or from about 0.100 inches toabout 0.125 inches. Further, laminates may be activated at commercialrates via, for example, the ring rolling activation process. Theactivation may occur immediately after the extrusion lamination processor may occur as the laminate is unwound from a roll on which it wasstored.

All of the multilayer films disclosed may be comprised in an outer coverof an absorbent article. For example, an absorbent article may comprisea topsheet, an outer cover, and an absorbent core disposed between thetopsheet and the outer cover, wherein the outer cover comprises alaminate comprising at least one nonwoven layer and at least onemultilayer film.

Combination Dual Bilaminates

In still other embodiments, two bilaminates with different stretch andrecovery properties may be combined to create new structures havingunique gradient stretch profiles. For example, a strip of high-recoverybilaminate may be applied over a portion of a base plastoelasticbilaminate that exhibits some larger measurable amount of permanent set.When the combination is subjected to a primary deformation cycle as theone produced by mechanical activation, regions can be created ofgathered materials within the base bilaminate adjacent to thehigh-recovery dual bilaminate due to the permanent shaping of theseadjacent regions and the differential in strain and recovery. Uponsubsequent loading, the dual bilaminate strip that includes thehigh-recovery bilaminate will stretch significantly more than thematerial in its vicinity and will recover over the entire range, unlikethe material in its vicinity that will exhibit deformation only beyond acertain strain value. Therefore, after the first stretch, the strip madeof the two bilaminates will be the first and only one to stretch anddeform again to the point where the adjacent plastoelastic would alsoparticipate in the deformation. The larger the plastic component in theplastoelastic bilaminate, the greater is the gathered appearance in theadjacent regions and the larger the strain value where the deformationis in the part of the fabrics. The ultimate amount of gathering may beachieved with a fully plastic film replacing a plastoelastic one, andthe trade-off is a lower residual elasticity in laminates with a greaterplastic component. The gathered effect may also be further accentuatedif the high-recovery top bilaminate is actually pre-strained and heldunder tension prior to being adhesively bonded to the bottom bilaminate.This type of multilayer laminate would be best suited for use in theconstruction of leg band or waistband features.

The two layers of bilaminates may be polyolefin-based films, which havegood processability. They may be made by extrusion lamination and drawndown to very thin layers at rates several times those to make extrudedfilms of, for instance, styrenic block copolymers.

In some embodiments, an absorbent article comprises a chassis compositestructure comprising a first bilaminate that is plastoelastic and thatexhibits a combination of nonrecoverable and recoverable stretch, with apercent recovery of strain (PRS), as measured by the Percent StrainRecovery Test (PSRT) from about 10% to about 95%, a second bilaminatethat is disposed on about 10% to about 100% of the area of the firstbilaminate, wherein the second bilaminate has at least the amount ofrecoverable stretch component as the first bilaminate (i.e, at least thesame or higher percent recovery of strain), and the combined bilaminateregions of the chassis have at most about 90 grams per square meterbasis weight. In some embodiments, at least one of the bilaminatesprovides 360 degree stretch in the cross-direction of the article. Thatis, when the absorbent article is in use, at least one of thebilaminates provides stretch around, for example, the waist of thewearer of the absorbent article. The bilaminate providing 360 degreestretch in the cross-direction of the article may overlap itself In someembodiments, one of the bilaminates may be folded onto itself prior tobeing attached to the other bilaminate. In some embodiments, thecombined first and second bilaminates provide stretch around, forexample, the waist of the wearer of the absorbent article. In someembodiments, a second bilaminate is disposed on about 10% to about 100%of the area of the first bilaminate.

In some embodiments, the stretchable regions or the regions of thechassis comprising at least one bilaminate may have less than about 90gsm basis weight. In some embodiments, any given dual bilaminate in anarticle may have a basis weight of at most about 90 gsm. In someembodiments, the total dual bilaminate basis weight in the article maybe at most about 90 gsm. In some embodiments, the first and secondbilaminates together may have a post activation tensile strength of atleast about 2 N/cm or at least about 3 N/cm or at least about 4 N/cm.Some embodiments may comprise a third bilaminate. In some embodiments,the first and second bilaminates may be bonded together, by an adhesive,via ultrasonic, thermal or pressure bonding, or via fusion during hotpinhole formation. In some embodiments, the first and second bilaminatesmay have a film portion that may be an elastomeric polyolefin, such asan elastomeric polyethylene, an elastomeric polypropylene, or ametallocene elastomeric polypropylene. In some embodiments, the firstand second bilaminates may have a film portion that is an elastomericolefin block co-polymer. In some embodiments, the second bilaminates mayhave a film portion that is a styrenic block co-polymer. In someembodiments, the first and second bilaminates are made by extrusionlamination.

In some embodiments, the second bilaminate may be prestrained prior tobeing disposed on the first bilaminate. In some embodiments, the chassisstructure has a machine direction and a cross direction, and the stretchelement of the chassis structure may be activated in either or both themachine or the cross direction. Further, the stretch element of thechassis structure may be activated in either or both the machinedirection or the cross direction with profiled activation (varied depthof engagement). In some embodiments, the tensile strength of theactivated chassis structure may be at least about 30% to about 100% ofthe tensile strength of the chassis structure prior to activation ineither or both the machine and/or cross direction. In some embodiments,the chassis composite structure may have a stiffener. In someembodiments, the article may be a pant with side seams, in others ataped article with fasteners situated at the edge of ear components, andin other embodiments, the article may further comprise a waistband, twolegbands, and two side sections, wherein one of the group consisting ofthe waistband, two legbands, and two side sections contains the secondbilaminate.

Dual Laminates for Stretchable Panels

In some embodiments, dual bilaminates may be used to construct thestretchable panels of an absorbent article. In some embodiments, thestretchable panels may be the back ears of a taped diaper or the sidepanels of a pant product.

Current taped product stretch back ears and pant side panels aretypically made with a relatively high basis weight (55-70 gsm) film ofstyrenic-based elastomeric core and polyolefin skin layers to helpalleviate its inherent tackiness. Strips of the film are adhesivelybonded onto a pair of nonwovens that require large amounts of adhesiveto hold the nonwovens onto the elastic film, especially in thestretch-activated regions. Such ears are typically activated to provideup to about 120% engineering strain at an applied force of 1 N/cm (asmeasured by the Tensile Test mode II) in these regions. The strength ofthe laminates comes in majority from the film, with only minimalcontributions coming from the adhesive layers and the activatednonwovens which sustain a large amount of damage during activation. Theears are combined to the chassis via compression point welding, whichcan pose challenges relating to different classes of materials andcompatibility.

In the present invention, each stretchable panel may comprise a strip ofa thin bilaminate joined to another bilaminate using a minimal amount ofadhesive, to create areas of dual bilaminate. These dual bilaminate backear and side panels have been found to offer unexpectedly far superiorproperties than the sum of the two components, in terms of toughness,and activation survivability.

One benefit from the dual bilaminate construction may be that, due toreduced costs, a wider strip of back ear or side panel material may beprovided. This can allow a larger area of material to be available foractivation, which in turn allows for either more stretch to be producedat equal depth of engagement (DOE) of the ring-rolls, or to have thesame amount of stretch produced at a lower DOE and therefore furtherminimizing any loss of strength in the activated nonwoven layers, oralternatively reducing the nonwoven basis weight requirement forstrength. Another benefit of a back ear with a larger area is lowerpressure on the skin of the wearer, which may reduce or eliminatered-marking and also better coverage of the skin. The high cost ofstyrenic-based films used in diaper side panels makes use of widerstrips of material prohibitive.

In some embodiments, the regions on the top of one bilaminate or inbetween the dual bilaminate could be the locus for unwinding astiffening precursor agent (such as a thick nonwoven layer, forinstance), which becomes a stiffening component using a compressionpoint welding-like overbonding process. Bonding patterns and selectionof stiffening precursor may be chosen to build up the most desirableamount of stiffness in selective locations. Adhesive may not benecessary to tack down the stiffening precursor prior to theoverbonding. The purpose of incorporating such stiffened regions is tomanage issues related to buckling or necking that are often typicallyassociated with drawn stretch laminates and may be undesirable to theconsumer in terms of aesthetics and wearing experience. The choice ofusing overbonding of a nonwoven precursor is motivated by theflexibility it provides in designing the right stiffness profile via theselection of the overbonding pattern.

Examples of such stretch back ear and side panel construction would beto consider making bilaminates with a tri-layer of film of anelastomeric polypropylene-based elastomeric core (such as Vistamaxx orVersify), with polyethylene-based skins (for example, Infuse andLLDPE/VLDPE blends), the film basis weight ranging from about 10 toabout 33 gsm. The film may alternatively be 5 or more layers of filmsfor the sake of improving their balance of properties. The bilaminatemay be fabricated at line speeds as high as about 300 ft/min, about 400ft/min, or about 500 ft/min. The nonwovens may be selected from avariety of extensible bico spunbond webs, with basis weights rangingfrom about 10 to about 25 gsm. Because little or no adhesive is used inthe construction of the bilaminates, there is no need for incorporatingone or more meltblown layers in the extensible spunbond nonwovenconstruction as this layer is typically included for the sole purpose ofproviding a barrier to glue bleedthrough.

Both bilaminates used in the back ear or side panel assembly may besimilar. However, the lower base bilaminate may have a total basisweight of about 20 to about 35 gsm (about 10 to about 25 gsm film andabout 10 to about 25 gsm nonwoven) and the top bilaminate may have abasis weight of about 20 to 58 gsm (about 10 to about 33 gsm film andabout 10 to about 25 gsm nonwoven). With about 2 to about 5 gsm ofadhesive, the total basis weight of the multilayer laminate region madeof the adhesive lamination of two bilaminates would range from about 45to about 98 gsm.

The stiffener could be produced by unwinding strips of a thick layer oflow cost polypropylene nonwoven at about 40 gsm to about 60 gsm andinserting them in between two bilaminate strips of the presentinvention. The embossing or compression welding could be performed withrolls mounted in parallel with the activation rolls or even as part of aseparate operation. The line could be run at speeds as high as about 300ft/min, about 400 ft/min, or about 500 ft/min. The localized stiffnessmay benefit specific regions of the outer cover, such as to reduce oreliminate unwanted buckling or folding, or in the case of back earlaminates, to change the stress distribution in the stretched state.

A specific example of a low-cost stretch back-ear may include a thinbase bilaminate of about 25 gsm (about 10 gsm film of Vistamaxx-basedfilm and about 15 gsm of a 50/50 PP/PE extensible spunbond SSS bico) andstrips of a thicker bilaminate of equal or higher intrinsic strength andstretch/recovery properties. The strips may be about 60 mm wide and maybe separated by about 20 mm and about 30 mm spaces in between. Thelatter Vistamaxx -based film may have a basis weight of about 30 gsm. Itmay include either a dispersed phase made of a TPE like Adflex or aStyrenics, or it may be coextruded with such elastomeric resins in a 4or more layered film. Or it may also simply be of the sameVistamaxx-based composition or have only some additional polypropylenedispersed in it to boost its strength. The nonwoven of the latterbilaminate may be of the same type as the other SSS bico with a higherbasis weight of about 20 gsm. A meltblown layer of adhesive may beapplied in the locations where the two bilaminates are connected.Finally strips of a high basis weight SSS spunbond polypropylene may beplaced outside the stretch areas in the locations where the tapes andhooks are located. Activation may be done at about a depth of engagementof about 5.5 mm with a set of intermeshing Ring Rolls that has a widthof about 60 mm and a pitch of about 3.81 mm, capable of producing astretch laminate with about 100% engineering strain at 1 N/cm in thecross direction, as measured by the Tensile Test (mode II). Theoverbonding pattern may be applied over those regions at roomtemperature and pressure sufficient to fuse the layers together but lowenough to not create holes.

In some embodiments, an absorbent article comprises a pair ofstretchable panels, each stretchable panel comprising a first bilaminatethat exhibits a percent recovery of strain (PRS) of at least about 80%,as measured by Percent Strain Recovery Test (PSRT); and a secondbilaminate that also exhibits a percent recovery of strain (PRS) of atleast about 80%; wherein the combined bilaminates of each stretchablepanel have no more than about 90 grams per square meter basis weight,and wherein the polymeric material of each bilaminate comprises at least50% by weight of polyolefin, or at least 60% by weight of polyolefin, orat least 70% by weight of polyolefin, or at least 80% by weight ofpolyolefin. The first and second bilaminates may be made by extrusionlamination. In some embodiments, each stretchable panel may be activatedin the machine direction and/or the cross direction. In someembodiments, the tensile strength of each stretchable panel may be atleast about 30% to about 100% of the tensile strength of the stretchablepanel prior to activation. In some embodiments, either or bothstretchable panels may, but may not necessarily, have a stiffener.

Extrusion Bonded Laminates

Extrusion bonded laminates (EBL's) are described in detail in USpublication 2010/0040826. In general, referring to FIGS. 1, 7, 8 and 9,EBLs of the present invention may include at least one nonwoven (NW1)(which may have multiple layers, e.g., SSS, SMS, SSMMS, SSM, etc.)joined to an elastomeric film (which may comprise multiple film layers(e.g., A1/B1/C1/B2/A2 or A1/B/A2)).

The elastomeric film of the present invention may comprise at least onetie outer layer (A1), at least two inner layers (B) comprising one ormore elastomeric components, and at least one additional polymeric layer(C) that is incorporated between two of the inner layers. In certainembodiments, laminates useful in absorbent article of the presentinvention may comprise a skin layer (A2), which may be compositionallyidentical to the tie layer. Further embodiments of the present inventionmay comprise two nonwovens such that (1) a first nonwoven (NW1) isjoined to the EBL via a first tie layer (A1) and a second nonwoven (NW2)is joined to the EBL via a second tie layer (A2) as illustrated in FIG.1 or (2) such that a first nonwoven (NW1) is joined to the EBL via a tielayer (A1) and a second nonwoven (NW2) is joined to the EBL via anadhesive) as illustrated in FIG. 6A. Still further, as shown in FIGS.6A, 6B, and 6C, embodiments of the present invention may include anonwoven joined to a film via a tie layer in combination with one ormore adhesives (which may be referred to as “adhesive assist”).Adhesives 1 and 2 may be compositionally identical or may be different.Further, adhesives 1 and 2 may be applied by the same or different means(e.g., adhesive 1 may be slot coated while adhesive 2 may be sprayed).

The following are descriptions of the types of materials that may bepresent in the extrusion bonded laminates:

A. Elastomeric Films

One or more layers of the elastomeric film (illustrated as layers A1,B1, C1, B2, and A2 in FIG. 1) may provide the desired amount ofextension and recovery forces during use of the laminate. As mentionedabove, the elastomeric film may comprise one or more film layers. Manysuitable elastic materials that may be used for one or more layers ofthe elastomeric film include synthetic or natural rubbers (e.g.,crosslinked polyisoprene, polybutadiene and their saturated versions(after hydrogenation), and polyisobutylene), thermoplastic elastomersbased on multi-block copolymers, such as those comprising copolymerizedrubber elastomeric blocks with polystyrene blocks (e.g.,styrene-isoprene-styrene, styrene-butadiene-styrene,styrene-ethylene/butylene-styrene, styrene-ethylene/propylene-styrene,and styrene-butadiene/isoprene-styrene, including their hydrogenated andnon-hydrogenated forms), thermoplastic elastomers based onpolyurethanes, polyesters, polyether amides, elastomeric polyolefinsincluding polyethylenes and polypropylenes, elastomeric polyolefinblends, and combinations thereof.

For instance, one useful group of elastomeric polymers that may be usedin the elastomeric film are the block copolymers of vinyl arylene andconjugated diene monomers, such as AB, ABA, ABC, or ABCA blockcopolymers where the A segments may comprise arylenes such aspolystyrene and the B and C segments (for those embodiments comprising Band/or C segments) may comprise dienes such as butadiene or isoprene. Asimilar, newer group of elastomeric polymers are the block copolymers ofvinyl arylene and hydrogenated olefin monomers, such as AB, ABA, ABC, orABCA block copolymers where the A segments may comprise arylenes such aspolystyrene and the B and C segments (for those embodiments comprising Band/or C segments) may comprise saturated olefins such as ethylene,propylene, or butylene. Suitable block copolymer resins are readilyavailable from KRATON® Polymers of Houston, Texas, Dexco™ Polymers LP ofPlanquemine, La., or Septon™ Company of America, Pasadena, Tex.

Another useful group of elastomeric polymers that may be used in theelastomeric film are olefin-based elastomers. In one embodiment, theelastomeric film comprises a polyolefinic elastomer (POE). Examples ofPOEs include olefin block copolymers (OBCs) which are elastomericcopolymers of polyethylene, sold under the trade name INFUSE™ by The DowChemical Company of Midland, Mich. Other examples of POEs includecopolymers of polypropylene and polyethylene, sold under the trade nameVISTAMAXX® by ExxonMobil Chemical Company of Houston, Tex. and/orVERSIFY by Dow Chemical, Midland, Mich.

For the elastomeric film, other polymers may be blended into thecompositions to enhance desired properties. For example, a linearlow-density polyethylene may be added to the film composition to lowerthe viscosity of the polymer melt and enhance the processability of theextruded film. High-density polyethylene may be added to preventage-related degradation of the other polymers. Polypropylene has beenfound to improve the robustness of the elastomer and improve the films'resistance to pinholing and tearing. Additionally, polypropylene-basedthermoplastic elastomer reactor blends (e.g., ADFLEX, available fromLyondellBasell Industries, Laporte, Tex.) may be used to increase thetoughness the film, as disclosed in WO 2007/146149.

Regarding elastomeric polypropylenes, in these materials propylenerepresents the majority component of the polymeric backbone, and as aresult, any residual crystallinity possesses the characteristics ofpolypropylene crystals. Residual crystalline entities embedded in thepropylene-based elastomeric molecular network may function as physicalcrosslinks, providing polymeric chain anchoring capabilities thatimprove the mechanical properties of the elastic network, such as highrecovery, low set and low force relaxation. Suitable examples ofelastomeric polypropylenes include an elastic randompoly(propylene/olefin) copolymer, an isotactic polypropylene containingstereoerrors, an isotactic/atactic polypropylene block copolymer, anisotactic polypropylene/random poly(propylene/olefin) copolymer blockcopolymer, a stereoblock elastomeric polypropylene, a syndiotacticpolypropylene block poly(ethylene-co-propylene) block syndiotacticpolypropylene triblock copolymer, an isotactic polypropylene blockregioirregular polypropylene block isotactic polypropylene triblockcopolymer, a polyethylene random (ethylene/olefin) copolymer blockcopolymer, a reactor blend polypropylene, a very low densitypolypropylene (or, equivalently, ultra low density polypropylene), ametallocene polypropylene, and combinations thereof. Suitablepolypropylene polymers including crystalline isotactic blocks andamorphous atactic blocks are described, for example, in U.S. Pat. Nos.6,559,262, 6,518,378, and 6,169,151. Suitable isotactic polypropylenewith stereoerrors along the polymer chain are described in U.S. Pat. No.6,555,643 and EP 1 256 594 A1. Suitable examples include elastomericrandom copolymers (RCPs) including propylene with a low level comonomer(e.g., ethylene or a higher alpha-olefin) incorporated into thebackbone. Suitable elastomeric RCP materials are available under thenames VISTAMAXX and VERSIFY as mentioned above.

In another embodiment, the inventive elastomeric film may comprisemultiple layers. Further, the elastomeric film may comprise a coextrudedmultilayer film with an ABA-type or ABCBA-type or ABCA-typeconstruction. The two A layers may comprise the same composition, andform the outer layers of the film, which may also be referred to as the‘skin,’ ‘surface,’ or ‘tie’ layers. In the present invention, the skinlayer may be compositionally identical to the tie layer. The B layer(s),which forms the ‘core’ or one or more inner layers, may becompositionally identical to the A layers, or the B layer may comprise acomposition other than the A layers. The C layer(s), which forms one ormore additional polymeric layer that is between two of the inner layers,may be compositionally identical to the A or the B layers, or the Clayer may comprise a composition other than the A or B layers. Eachlayer of a multilayer elastomeric film may comprise elastomericpolymers, or the layers may comprise either elastomeric or thermoplasticnon-elastomeric polymers, either singly or in combination, in eachlayer.

For the embodiment in which the elastomeric film is a multilayer film ofABA or ABCBA construction, the A layers, which are the skin or tielayers, may comprise an elastomeric polymer. For the A layers, the useof polyolefin-based elastomers may be desired. It has been unexpectedlydiscovered that A layers comprising POEs improve the processability ofthe elastomeric film, as discussed above, even when the core layer is astyrene block copolymer (SBC) or other less-processable polymer. Also asdiscussed above, POEs on the surface of the film may have a greaterchemical affinity for a polyolefinic fabric joined to the surface of thefilm in the laminate. This greater chemical affinity may improve thelaminate strength between the film surface and a nonwoven.

The inner B layers of the multilayer elastomeric film (e.g.,A1/B1/C1/B2/A2 or A1/B/A2), may comprise any elastomeric polymer. In oneembodiment, one or more of the inner layers, or the additional polymericlayer, C, or both may be an SBC, such as styrene-butadiene-styrene(SBS), styrene-isoprene-styrene (SIS), styrene-ethylenebutadiene-styrene(SEBS), styrene-ethylene-propylene (SEP),styrene-ethylene-propylene-styrene (SEPS), orstyrene-ethylene-ethylene-propylene-styrene (SEEPS) block copolymerelastomers, or blends thereof. SBC elastomers exhibit superiorelastomeric properties. The presence of SBC elastomers in the multilayerelastomeric film yields a film that has excellent stretch and recoverycharacteristics. As discussed previously, however, unsaturated SBCelastomers are prone to thermal degradation when they are overheated,and saturated SBC's tend to be very expensive. Additionally, SBC's canbe difficult to process and extrude into films, especially thin films ofthe present invention. In another embodiment, the inner B layers of themultilayer film, may be a thermoplastic polyolefin, such as theelastomeric polypropylenes mentioned above, the olefin block copolymersof predominantly ethylene monomers mentioned above, thepolypropylene-based thermoplastic elastomer reactor blends mentionedabove, and combinations thereof. In another embodiment, the inner Blayers of the multilayer film may comprise an SBC and a thermoplasticpolyolefin.

In addition to the elastomeric polymer in the inner layers of themultilayered film, other polymeric components may be added to the innerlayer composition to improve the properties of the film. For example, alinear low-density polyethylene may be added to the film composition tolower the viscosity of the polymer melt and enhance the processabilityof the extruded film. High-density polyethylene may be added to preventage-related degradation of the other polymers. High-impact polystyrene(HIPS) has been found to control the film modulus, improve the toughnessof the film, and reduce the overall cost of the elastomeric material.

In the present invention, homopolymer polypropylene (hPP) may be blendedinto one or more of the inner layers (B) or into an additional polymericlayer (C) composition to improve processability. hPP is a form ofpolypropylene which is highly crystalline and containing essentially100% propylene monomer. It has been found that SBC-based elastomericfilms with hPP can be extruded at a thinner gauge and with improvedgauge uniformity, and the addition of hPP may reduce the tendency of thefilm to experience draw resonance during extrusion.

The elastomeric film of the present invention may optionally compriseother components to modify the film properties, aid in the processing ofthe film, or modify the appearance of the film. Viscosity-reducingpolymers and plasticizers may be added as processing aids. Otheradditives such as pigments, dyes, antioxidants, antistatic agents, slipagents, foaming agents, heat and/or light stabilizers, and inorganicand/or organic fillers may be added. These additives may optionally bepresent in one, several, or all layers of a multilayer elastomeric film.

In order to manufacture a thin-gauge elastomeric film, the average basisweight of the elastomeric film may be controlled. If a polymer is hardto process, then the extruded film of that polymer will likely be hardto control. This lack of control is seen in problems like fluctuatingbasis weights, draw resonance, web tear-offs, and other significantproblems. As discussed above, SBC elastomers tend to have relativelypoor processability, and hence it is very hard to manufacture a filmwith a controlled basis weight. These problems are only magnified as oneattempts to manufacture a film with a lower basis weight.

However, by extruding films comprising POE polymers or, alternatively,POE polymer outer layers (e.g., tie or skin layers), the processabilityof the elastomeric film is improved, and the problems associated withbasis weight control are reduced or eliminated. The inventors havediscovered that thin-gauge films are much easier to manufacture, evenwith high concentrations of SBCs in the core layer, when the outerlayers comprise POE polymers.

Another problem with manufacturing lower basis-weight films is theirreduced mass, which causes the extruded polymer web to solidify morerapidly. If the extruded polymer web solidifies too quickly, then thepolymer film is ‘locked’ into the thickness that exists at that time.This situation is directly comparable to the ‘frost line’ experienced inblown film technology. Once the film has solidified, it cannot be easilydrawn to a thinner gauge. This is particularly a problem with elastomerslike unsaturated SBCs, which are prone to thermal degradation whenheated to excessively high temperatures. Simply heating the unsaturatedSBC to a higher temperature to compensate for the reduced mass of theextruded web may not be sufficient.

POE elastomeric polymers, however, are more thermally stable than SBCelastomers, and thus, can be heated to a higher temperature withoutdegradation. This increases the total heat present in the extrudedpolymer web, so the web releases more heat before solidifying. POEs alsosolidify at lower temperatures than do SBCs, so there is a greaterdifferential between the temperature of the extruded polymer and thetemperature at which the film solidifies. The inventors have alsodiscovered, unexpectedly, that coextruding an SBC-based core withinPOE-based outer layers both allows the coextruded multilayer film to beextruded at a higher overall temperature, thereby compensating somewhatfor the reduced-mass heat loss, and also increases the time it takes forthe molten extrudate to solidify. This allows the manufacturer toextrude the multilayer elastomeric polymer film and draw it to a lowerbasis weight before the film solidifies.

It may be desirable for certain aspects of the present invention to usean elastic film that is less than about 65 gsm, or less than about 40gsm, or less than about 30 gsm, or less than about 20 gsm, or less thanabout 15 gsm, or less than about 10 gsm, but greater than about 1 gsm orabout 5 gsm. The approximate basis weights of the films may be measuredaccording to the commonly understood method referred to as “massbalance.” Further, thicknesses of the films may be determined using SEMor optical microscopy. Elastic films of the present invention may have athickness or caliper (also known as z-direction thickness) in the rangeof about 1 μm to about 65 μm, or from about 1 μm to about 40 μm, or fromabout 1 μm to about 30 μm, or from about 1 μm to about 20 μm, or fromabout 1 μm to about 15 μm, or from about 1 μm to about 10 μm.

Nonwovens

The elastomeric film may be combined with a nonwoven. The nonwovens(illustrated as NW1 and NW2 in FIG. 1) may be activatable sheet-likematerials, such as fabrics. The nonwoven of the present invention isgenerally formed from fibers which are interlaid in an irregular fashionusing such processes as meltblowing, air laying, coforming, and carding.In some embodiments, the nonwoven may include spunbond fibers in asingle layer (S) or multiple layers (SSS). In other embodiments, fibersof different diameters or compositions may be blended together in asingle layer, or fibers of different diameters or compositions may bepresent in multiple layers, as in spunbond-meltblown-spunbond (SMS)constructions, spunbond-spunbond-meltblown (SSM) constructions, andspunbond-spunbond-meltblown-meltblown-spunbond (SSMMS) constructions.The fibers of the nonwoven material may be joined together usingconventional techniques, such as thermal point bonding, ultrasonic pointbonding, adhesive pattern bonding, and adhesive spray bonding. Examplesof activatable nonwovens useful in the present invention include thosedescribed in U.S. Pat. No. 6,417,121. It may be desirable to useextensible nonwoven fabrics that comprise fibers derived from renewableresources. For example, a nonwoven that comprises multicomponent fiberswith a sheath-core configuration wherein the sheath comprises one ormore thermoplastic polymers and the core comprises thermoplastic starch,as described in U.S. Pat. No. 6,623,854 B2 by E. Bond, and U.S.application Ser. No. 09/853,131, 09/852,888).

These fabrics may comprise fibers of polyolefins such as polypropyleneor polyethylene, polyesters, polyamides, polyurethanes, elastomers,rayon, cellulose, thermoplastic starch, copolymers thereof, or blendsthereof or mixtures thereof. For a detailed description of nonwovens,see “Nonwoven Fabric Primer and Reference Sampler” by E. A. Vaughn,Association of the Nonwoven Fabrics Industry, 3d Edition (1992).

One or more components or layers of the nonwoven may comprisebicomponent fibers. The bicomponent fiber may be of any suitableconfiguration. Exemplary configurations include but are not limited tosheath-core, island-in-the-sea, side-by-side, segmented pie andcombinations thereof (as disclosed in U.S. Pat. No. 5,405,682). In oneoptional embodiment of the present invention the bicomponent fibers havea sheath-core configuration. The sheath may be predominately comprisedof polyethylene and the core may be predominately comprised ofpolypropylene. These fibers may have a diameter or equivalent diameterof from about 0.5 micron to about 200 microns or from about 10 and toabout 40 microns.

Typically, the bicomponent fibers described above are consolidated intoa nonwoven web. Consolidation can be achieved by methods that apply heatand/or pressure to the fibrous web, such as thermal spot (i.e., point)bonding. Thermal point bonding can be accomplished by passing thefibrous web through a pressure nip formed by two rolls, one of which isheated and contains a plurality of raised points on its surface, as isdescribed in U.S. Pat. No. 3,855,046. Consolidation methods can alsoinclude, but are not limited to, ultrasonic bonding, through-airbonding, resin bonding, and hydroentanglement. Hydroentanglementtypically involves treatment of the fibrous web with high pressure waterjets to consolidate the web via mechanical fiber entanglement (friction)in the region desired to be consolidated, with the sites being formed inthe area of fiber entanglement. The fibers can be hydroentangled astaught in U.S. Pat. Nos. 4,021,284 and 4,024,612.

All shapes of fibers may be used to form the nonwoven of the presentinvention. Nonwovens comprising “flat” fibers, such as fibers that arerectangular or oblong in cross section, however, may be better joined tothe elastomeric film than nonwoven fabrics with fibers that are circularin cross section. Additionally, notched fibers may be used (i.e.,multilobal, including bilobal and trilobal fibers).

The nonwoven of the present invention may have a basis weight of about 5grams per square meter (gsm) to 75 gsm. In one embodiment, the nonwovenfabric has a basis weight from about 5 to about 30 gsm. Unless otherwisenoted, basis weights disclosed herein are determined using EuropeanDisposables and Nonwovens Association (“EDANA”) method 40.3-90.

Tie Layers

Controlling the bond strength between the elastomeric film and thenonwoven of the elastomeric laminate is an important aspect. Bondstrength may be measured using Mode II peel as described under TestMethods. Improved bond strength between the layers can be achieved by anumber of ways, depending on the lamination method. If the layers arelaminated by an adhesive method, the choice of adhesive, amount ofadhesive, and pattern of adhesive applied to bond the layers can beadjusted to achieve the desired bond strength. Additionally, for EBLs,bond strength between film and the nonwoven may be controlled by use ofa tie layer (illustrated as A1 and A2 in FIG. 1) that may be selected tooptimize (including increasing or decreasing the bond strength) thechemical affinity between the film and nonwoven. In particular, tielayers that contain copolymers of ethylene and propylene, or blends ofethylene- and propylene-based polymers, can be “tuned” to provideoptimal chemical affinity with the nonwoven by appropriate choice of thecopolymer's ethylene content. For example, in a laminate comprising abicomponent nonwoven with a polyethylene sheath, a tie layer containingPE homopolymer may have too great a chemical affinity with the nonwovenwhereas a tie layer containing PP homopolymer generally has too littlechemical affinity. A tie layer comprising an ethylene-propylenecopolymer with intermediate ethylene contents (10-97 wt. %) provides thechemical affinity required for optimal adhesion between film andnonwoven: enough adhesion to avoid delamination but not enough to causeunwanted pinholes in the film during the activation process.

When the layers making up the film are laminated by an extrusionlamination process, the properties of the film must be carefullyselected to manage competing requirements of throughput, bonding, webtension and control, winding, unwinding, and activation, among others.In the case the extruded elastomeric film of the present invention is ofthin gauge (less than about 30 gsm), the extruded film has less mass toretain heat during the extrusion process. Less mass means that theextruded molten laminate tends to solidify very rapidly. As discussedpreviously, this rapid solidification creates problems when trying tomanufacture thinner films. Additionally, if the extruded elastomericfilm solidifies too rapidly, it is harder to achieve adequate bondstrength between the extruded elastomeric film and any nonwovens in anextrusion laminate. This is particularly a problem when the extrudedpolymer of the elastomeric film does not have great chemical affinityfor the materials that comprise the nonwoven substrate. For instance,SBC elastomers do not have strong natural chemical affinity for thepolyolefinic materials typically used for nonwoven substrates. In orderto achieve adequate bond, laminates of SBC elastomers and nonwovensubstrates must rely on mechanical bonding forces, such as thoseachieved by embedding the fibers of the nonwoven into the surface of theelastomeric film. Unfortunately, if the film has solidified beforecontacting the nonwoven, the fibers of the nonwoven cannot be embeddedinto the solidified surface of the film without application ofsignificant pressure. Hence, the bond strength between the layers of thelaminate is poor, and the elastomeric material will tend to delaminateeasily. Furthermore, with the thin gauges of the elastomeric films ofthe present invention, any significant penetration of the fibers intothe film, or deformation of the film from nip or other bonding pressure,may result in unacceptably thin regions of the film that may tear duringsubsequent processing or handling. In still other cases, the chemicalaffinity of the elastomeric film may be sufficiently high that anacceptable laminate bond strength is obtained, but the laminate may bedifficult to activate due to a number of reasons that may include theintimate coupling of the nonwoven substrate and the film during theactivation process.

Furthermore, the high chemical affinity of the elastomeric film for thenonwoven may cause issues in storing, transporting and unwinding of thelaminate, if the chemical affinity leads to roll blocking.

Regarding this problem, POE elastomers, however, have more chemicalaffinity for the polyolefinic materials in nonwoven, because the POEsare themselves polyolefinic materials. The chemical affinity of POEs fornonwovens means that these laminate layers are more apt to bond, evenwith little mechanical bonding from embedded nonwoven substrate fibers.In addition, because the thin POE-based films do not solidify as rapidlyas the SBC-based materials, the extruded elastomeric film is stillsemi-molten and soft when it contacts the nonwoven, which allows thenonwoven fibers to embed into the film's surface. Hence, the inventorshave observed that POE-based elastomeric films, or alternativelymultilayer elastomeric films comprising POE-based tie layers, formlaminates with stronger bond strength and less tendency to delaminatewith bicomponent nonwovens comprising a PE sheath. The POE-based skinand tie layers of the present invention may be chosen in such a way asto optimize bonding to the nonwoven during the extrusion step ofmanufacture while providing a tack-free surface to allow winding andstorage of bilaminate EBL with little roll blocking.

A further means to improve the bonding of a tie layer to a nonwoven inan EBL of the present invention is by control of the rate ofcrystallization of a polymer or blend of polymers comprising the tielayer. This has many advantages in the thin films of the presentinvention. When taken together with the chemical affinity of the tielayer for a surface of the nonwoven, the rate of crystallization mayfacilitate or limit the penetration of fibers into the surface. Forexample, when a blend of polymers is chosen with a high crystallizationrate, an outer facing surface of the film may be reinforced andstrengthened to resist deformation when contacting a fibrous surface ofa nonwoven in the nip of an extrusion lamination process, withbeneficial effects on the film quality. Of course, too rapid of acrystallization may result in an outer surface that is so resistant toflow that adequate contact with a nonwoven surface is not achieved. Inanother example, therefore, a polymer blend is chosen to reduce the rateof crystallization so that an outer facing surface of the film mayremain soft and able to flow, increasing the contact area and contacttime of a tie layer and nonwoven in an extrusion lamination process. Oneof ordinary skill in the art will recognize that the rate ofcrystallization may be further adjusted by means of nucleation aids,shear conditions, process temperature, plasticizers, and the like, andthat the rate of crystallization may have limited or even no impact onthe fusion index of EBLs useful in absorbent articles of the presentinvention. Crystallization rates of tie layers useful in EBLs of thepresent invention range from about 1 second to about 60 seconds, fromabout 3 seconds to about 30 seconds, or from about 5 seconds to about 20seconds.

Skin Layers

A challenge of using elastomeric films is that the polymers used to makethe films are inherently sticky or tacky. When elastomeric films areextruded and wound into a roll, the film will tend to stick to itself or“block,” thereby becoming difficult or impossible to unwind. Blockingbecomes more pronounced as the film is aged or stored in a warmenvironment, such as inside a storage warehouse. A similar problemexists when an elastomeric film is extruded onto a nonwoven to make abilaminate and wound onto a roll, since a tacky surface of the film willcome into intimate contact with a substantial portion of an oppositesurface of the bilaminate when wound. This may prevent unwinding of theroll at commercial speeds in the process of making absorbent articlesand may lead to damage to the film, the nonwoven, or to both.

These problems can be addressed in a number of ways. For instance,antiblocking agents may be used. Antiblocking agents, which are usuallyinorganic particulate materials such as silica or talc, can beincorporated within one or more layers of the film. Antiblocking agentscan also be dusted onto the outer surfaces of extruded film as the filmis being formed. The elastomeric film can also be surface-coated withmaterials that are not sticky, such as a nonblocking polymer, a brittlenonblocking polymer, a surface coating such as a lacquer or ink, andother such powder coatings. Another way to solve this problem is tocoextrude a non-tacky skin layer (illustrated as A2 in FIG. 1—when NW2is not present) as part of the film. The skin layer may be identical(chemically and/or physically) to the tie layer. Thus, referring to FIG.1, if NW2 is present, A2 may act as a second tie layer. If, however, A2forms an exterior surface of the laminate, it may act as a skin layer.In the latter case, a nonwoven, or a second bilaminate may be joined toit in a separate process later in time via an adhesive or other bondingmeans (including, thermal bonds, radio frequency bonds, pressure bonds,ultrasonic bonds, welds, stitching, and the like).

The fusion index for the tie and/or the skin layers of the presentinvention may be from about 14% to about 40%. The fusion index for thepolyethylene portion of the nonwoven of the present invention may befrom about 80% to about 100%. And, the fusion index for thepolypropylene portion of the nonwoven of the present invention may begreater than about 50%. Further, the fusion index for the inner layersof the multilayer film of the present invention comprising thermoplasticpolyolefin elastomers may be from about 10% to about 30%.

Skin layers of the present invention may comprise less than 60% of thevolume of the multilayered film. In other embodiments, the skin layersof the present invention may comprise less than 50%, less than 40%, lessthan 25%, less than 20%, less than 15%, less than 10% or less than 3% ofthe volume of the multilayered film. It may be desirable to have a skinlayer and tie layer which are compositionally identical.

Draw Down Polymers

One or a combination of layers of the EBL may comprise one or acombination of draw down polymers. In embodiments where one or acombination of draw down polymers are present in two or more layers, theamount of draw down polymer (in weight percent) in each layer may beequal or different. Further, the composition of a draw down polymer orblend of draw down polymers present in a first layer may becompositionally identical to or distinct from a draw down polymer orblend of draw down polymers present in a second layer. The draw downpolymer is a polymer that adds or enhances one or more film propertiesor processing properties, such as those that aid in processabilityduring film preparation. For example, the draw down polymer can aid inthe production of reduced-gauge (i.e., thin) films. In some embodiments,the draw down polymer can aid in film extrusion, such as by helping toprovide an increased line speed or reduce draw resonance. Other possibleprocessability benefits from the addition of the draw down polymerinclude improving the melt curtain stability, providing a smooth filmsurface, providing a lower viscosity of the polymer melt, providingbetter resistance to heat (e.g., increasing the film's heat capacity orthermal stability), providing resistance to tearing, providingresistance to pinhole formation, providing a controlled and uniformthickness, or providing a homogeneous composition. The draw down polymercan act as a processing aid that lubricates the die to reduce sticking(e.g., of elastomeric polymers) and flow resistance of the moltenelastomeric resin. Of course, the addition of the draw down polymer canprovide one or a combination of these aids to film extrusion orprocessability.

There are many examples of draw down polymers. For example, a linearlow-density polyethylene (e.g., ELITE™ 5800 provided by Dow ChemicalCorp. of Midland, Mich.) can be added to a layer of the film compositionto lower the viscosity of the polymer melt and enhance theprocessability of the extruded film. High-impact polystyrene (HIPS)(e.g., STYRON™ 485 from Dow Chemical Corp. of Midland, Mich.; IneosNova473D from IneosNova of Channahon, Ill.) can help control the filmmodulus, improve the toughness of the film, and reduce the overall costof the elastomeric material. Polypropylene can improve the robustness ofthe elastomer and improve the films' resistance to pinholing andtearing. Homopolymer polypropylene (hPP) (e.g., INSPIRE™ D118 from DowChemical Corp. of Midland, Mich.; Polypropylene 3622 from TotalPetrochemicals of Houston, Tex.) can be added to improve processability.hPP is a form of polypropylene which is highly crystalline andcontaining essentially 100% propylene monomer. In some embodiments, hPPis added to a layer comprising an elastomeric polymer (e.g., styreneblock copolymers), as discussed below; the addition can result, in someinstances, in a film that can be extruded at a thinner gauge, withimproved gauge uniformity, or with reduced tendency to experience drawresonance during extrusion.

The draw down polymers can be linear low density polyethylene,propylene, homopolymer polypropylene, high impact polystyrene, andmixtures thereof. The draw down polymer can be a polymer which has beenprepared using a single-site catalyst such as a metallocene catalyst andcan be, for example, a polyolefin produced using a metallocene catalyst(e.g., ELITE' 5800 provided by

Dow Chemical Corp. of Midland, Mich.). The identity and amount of drawdown polymer can depend on the other components in the layer (e.g., theidentity of the olefin-based elastomeric polymer(s) in the layer), othercomponents of the film or, if applicable, components of the laminatethat comprises the film. The total amount of draw down polymer can bepresent in an amount effective to enhance one or more film propertiesthat aid in processability during film preparation; for example, thetotal amount of draw down polymer can be present in an amount effectiveto provide a film gauge of about 25 gsm, about 20 gsm, about 15 gsm, orabout 10 gsm. The total amount of draw down polymer (i.e., the combinedamount of the one or more draw down polymer(s)) can be at least about5%, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, about55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %,about 80 wt %, about 85 wt %, about 90 wt %, or about 95 wt % of a layer(i.e., total weight of draw down polymer(s) divided by the total weightof the layer). In some instances the total amount of the draw downpolymer is at least about 5 wt %, at least about 10 wt %, at least about20 wt %, or at least about 45 wt % of the EBL.

Adhesives

Referring to FIG. 1, an adhesive may be used between the NW1 and A1and/or between A2 and NW2. The adhesive may be a hot-melt adhesiveapplied via a slot coater and/or sprayer, for example. According to oneembodiment, the adhesive may be H2031, H2401, or H2861, which arecommercially available from Bostik Inc. of Wauwatosa, Wis. Usingadhesive assist, the adhesive may be applied during the fabrication ofthe EBL by applying it to a surface of the nonwoven (e.g., NW1) justprior to joining the film extrudate, particularly, the tie layer (e.g.,A1). Further, a second nonwoven (e.g., NW2) may be adhesively laminatedwith an outer layer (e.g., A2) of an EBL according to the presentinvention. Still Further, the EBL of the present invention (which mayinclude a first and second nonwoven (e.g., NW1 and NW2, respectively)may be adhesively joined to one or more components of an absorbentarticle, including an absorbent core, a waistband, a cuff, a topsheet,etc. Still Further, the EBL of the present invention, which includes afirst nonwoven (e.g., NW1) may be joined to a second EBL by adhesivelybonding together the outer skin layers of the two EBLs, wherein thefirst EBL and the second EBL may be the same or different.

Absorbent Articles of the Present Invention

The multilayer laminates and dual bilaminates of the present inventionmay make up at least a portion of one or more components of an absorbentarticle, including a backsheet, an outer cover, a side panel, awaistband, a front- or back-ear, and combinations thereof. For instance,the multilayer laminates and dual bilaminates of the present inventionmay make up a portion of the pant or diaper outer cover disclosed inU.S. Pub. Nos. 2005/0171499, 2008/0208155, 2007/0167929, and2008-0045917. The laminates and bilaminates may be subjected toadditional processing steps before or after incorporation into anabsorbent article. For example, one or more components of the absorbentarticle comprising the laminates may be activated by passing it throughintermeshing wheels (ring rolls) to incrementally stretch and deform orbreak-up the nonwoven, tie, and/or skin layers in either or both CD andMD. Further, one or more components of the absorbent article comprisingthe laminates may be apertured to improve air flow and WVTR through thematerial and improve the comfort of the absorbent article when worn. TheEBL may be printed, embossed, textured, or similarly modified to improvethe aesthetics of the absorbent article or even to provide some functionor feedback to the wearer.

FIGS. 2 and 3 show an absorbent article (illustrated as a pant-likediaper 20) constructed in accordance with the present invention. Thediaper 20 has a longitudinal centerline 100 and a lateral centerline110. The diaper 20 defines an inner surface 50 and an opposing outersurface 52. The inner surface 50 generally includes that portion of thediaper 20 which is positioned adjacent the wearer's body during use(i.e., the wearer-facing side), while the outer surface 52 generallycomprises that portion of the diaper 20 which is positioned away fromthe wearer's body (i.e., the garment-facing side).

The diaper 20, includes a chassis 21 having a first, or front, waistregion 36, a second, or back, waist region 38 opposed to the front waistregion 36, and a crotch region 37 located between the front waist region36 and the back waist region 38. The waist regions 36 and 38 generallyinclude those portions of the diaper 20 which, when the diaper 20 worn,encircle the waist of the wearer. The waist regions 36 and 38 caninclude elastic elements such that they gather about the waist of thewearer to provide improved fit and containment. The waist regions 36 and38 of a taped diaper can be fastened around the waist by use of afastening system, such as tabs located in the back waist region 38,which may be fastened to the front waist region 36 The crotch region 37is that portion of the diaper 20 which, when the diaper 20 is worn, isgenerally positioned between the legs of the wearer.

The outer periphery of the chassis 21 is defined by lateral end edges 56that can be oriented generally parallel to the lateral centerline 110,and by longitudinal side edges 54 that can be oriented generallyparallel to the longitudinal centerline 100 or, for better fit, can becurved or angled, as illustrated, to produce an “hourglass” shapedgarment when viewed in a plan view. In some embodiments, thelongitudinal centerline 100 can bisect the end edges 56 while thelateral centerline 110 can bisect the side edges 54.

The chassis 21 of the diaper 20 generally includes a liquid-permeabletopsheet 22, an outer cover 24, and an absorbent core assembly 23disposed between the topsheet 22 and the outer cover 24.

The core assembly 23 can be positioned on a wearer-facing surface of theouter cover 24. The core assembly 23 can be joined to the outer cover 24via any suitable adhesive or cohesive 32 (as illustrated) or via anyother suitable means known in the art (e.g., thermal bonds, radiofrequency bonds, pressure bonds, ultrasonic bonds, welds, stitching, andthe like). In some embodiments, the core assembly 23 is attached to theouter cover 24 in as few locations as possible; this can make the outercover 24 look and feel softer. Suitable examples for attaching the coreassembly 23 to the outer cover 24 include the attachment means describedin U.S. Pub. No. 2007/0287982. Other suitable examples for attaching thecore assembly to the outer cover include the attachment means describedU.S. Pub. No. 2007/0287983.

On the other hand, in order to make the design more tamper-resistant, itmay be desirable to attach the core assembly 23 to the outer cover 24along at least part, if not all, of the core assembly's 23 periphery; ora small distance (about 5-20 mm) inboard of the periphery. For example,the bond area between the core assembly 23 and the outer cover 24 can beless than about 70%, or, as another example, less than about 50%, or, asyet another example, less than about 20% of the core assembly 23 surfacearea that is attached to the outer cover 24.

The core assembly 23 is the portion of the diaper 20 providing much ofthe absorptive and containment function. The absorbent core assembly 23includes an absorbent core 26, both of which can be disposedsymmetrically or asymmetrically with respect to either or both of thelongitudinal centerline 100 and/or the lateral centerline 110. Asillustrated, the absorbent core 26 and core assembly 23 are symmetricalwith respect to both the longitudinal centerline 100 and the lateralcenterline 110.

The absorbent core 26 can include a wide variety of liquid-absorbentmaterials commonly used in disposable diapers and other absorbentarticles. Examples of suitable absorbent materials include comminutedwood pulp (e.g., air felt creped cellulose wadding); melt blown polymersincluding co-form; chemically stiffened, modified or cross-linkedcellulosic fibers; wraps and tissue laminates; absorbent foams;absorbent sponges; superabsorbent polymers; absorbent gelling materials;or any other known absorbent material or combinations of materials. Theabsorbent core 26 can include (1) a fluid-acquisition component whichacquires fluid exudates and partitions the exudates away from a wearer'sbody, (2) a fluid-distribution component which redistributes fluidexudates to locations displaced from the point of initial exudateloading, and/or (3) a fluid-storage component which retains a majorityof the fluid exudates on a weight basis. A suitable absorbent corecomprising an acquisition layer, a distribution layer, and/or a storagelayer is described in U.S. Pat. No. 6,013,589. A suitable absorbent corehaving minimal absorbent fibrous material (i.e., not more than about 20wt. % based on the weight of the absorbent core) within the absorbentcore is described in U.S. 2004/0167486. Other suitable absorbent coreconfigurations are discussed in U.S. Pub. Nos. 2003/0225382,2006/0155253, and 2006/0155254. It may be desirable to have an absorbentcore and/or absorbent assembly that is free of or substantially free ofany absorbent fibrous material (i.e., air-felt free) as described inU.S. Pub. No. 2005/0171499.

In some embodiments, the core assembly 23 can include a containmentmember 28, such that the absorbent core 26 is disposed between thetopsheet 22 and the containment member 28. In some embodiments, thecontainment member 28 covers a garment-facing surface of the absorbentcore 26, at least in part, and extends laterally beyond the core 26. Thecontainment member 28 can also extend upwardly to cover the lateralsides of the absorbent core 26. The containment member 28 can beconstructed from a woven web, a nonwoven web (with synthetic and/ornatural fibers), an apertured film, and a composite or laminate of anyof the aforementioned materials. In certain embodiments, the containmentmember 28 is an air permeable nonwoven web such as described in U.S.Pat. No. 4,888,231.

The absorbent core assembly can also include a core cover 29 disposed ona wearer-facing surface of the absorbent core 26. The core cover 29 canhelp immobilize the liquid absorbent material of the absorbent core 26.The core cover 29 may generally be a liquid pervious material, such as anonwoven material or tissue.

The components of the core assembly 23 can be joined as described viaany suitable adhesive or cohesive or via any other suitable means knownin the art. Any of the aforementioned layers of the core assembly 23 canbe a single material or can be a laminate or other combination of two ormore materials.

As illustrated, the topsheet 22 is a distinct structural unit thatcovers the absorbent core 23 and may be attached to the outer cover 24,for example via the adhesive or cohesive 32, thereby forming anenclosure for the absorbent core. In an alternate embodiment (notshown), the core assembly 23 can be self-contained by integrating thetopsheet 22 into the core assembly 23, for example by disposing thetopsheet 22 adjacent a body-facing surface of the core cover 29. Thetopsheet 22 can be made from any suitable liquid-permeable material, forexample those described in U.S. Pat. No. 3,860,003, U.S. Pat. No.5,151,092, and U.S. Pat. No. 5,221,274.

As shown, a pair of opposing and longitudinally extending leg cuffs 35are disposed on and extend outwardly from the topsheet 22. The leg cuffs35 provide a seal against the wearer's body and improve containment ofliquids and other body exudates. In the alternate embodiment (not shown)described above in which the core assembly 23 is self-contained andincludes the topsheet 22, the leg cuffs 35 can simply be the extensionof the laterally distal ends of the containment member 28.

The diaper 20 can also include a waistband 43 that generally forms atleast a portion of the end edge 56 and/or a leg elastic (not shown) thatgenerally forms at least a portion of the side edges 54. The waistband43 and leg elastic are those portions of the diaper 20 which areintended to elastically expand and contract to dynamically fit thewearer's waist and legs, respectively, to provide improved fit andcontainment. The elastic waistband 43 can include a segment positionedin the front waist region 36 and/or the back waist region 38, and can bediscretely attached or an integral part of the chassis 21. Examples ofsuitable waistbands include those described in U.S. Pat. No. 4,515,595,U.S. Pat. No. 5,151,092, and U.S. Pat. No. 5,221,274.

The diaper 20 can be preformed by the manufacturer to create a pull-ondiaper or pant, and the diaper can be prefastened by the manufacturer orfastened by the consumer prior to wearing. Specifically, the diaper 20may include left and right closed side seams 34, each disposed atregions proximal to the front and back ends of side edges 54. Each sideseam 34 can be closed by buttressing and subsequently attaching a givenside edge 54 in the front and back waist regions 36 and 38 either usinga permanent seam or refastenable closure member. Suitable permanentseams include, for example, heat seals, adhesive bonds, ultrasonicbonds, high pressure bonds, radio frequency bonds, hot air bonds, heatedpoint bonds, and combinations thereof. Suitable refastenable closuremembers include, for example, hook and loop fasteners, hook and hookfasteners, macrofasteners, tape fasteners, adhesive fasteners, cohesivefasteners, magnetic fasteners, hermaphrodidic fasteners, buttons, snaps,and tab and slot fasteners. The side edges 54 can alternatively beattached in an exterior surface-to-exterior surface configuration,interior surface-to-interior surface configuration, or interiorsurface-to-exterior surface (overlapping) configuration.

When in use, the pull-on diaper 20 is worn on the lower torso of awearer, such that the end edges 56 encircle the waist of the wearerwhile, at the same time, the chassis side edges 54 define leg openingsthat receive the legs of the wearer. The crotch region 37 is generallypositioned between the legs of the wearer, such that the absorbent core26 extends from the front waist region 36 through the crotch region 37to the back waist region 38.

In another embodiment (not shown), the principles of the presentinvention as described above with respect to pant-like garments can beequally applied to absorbent articles that are configured as tapeddiapers. In this embodiment, the diapers are not closed prior towearing. Instead, the diapers generally include side panels havingengaging elements. The side panels can be attached to the diaper chassisat either or both of the front and rear waist regions such that theengaging elements, when worn, contact some portion of the diaper on theopposing waist region to seal the diaper. Examples of suitable diapersaccording to the present invention are described in U.S. Pub. No.2008/0114326.

Examples of the Present Invention

Examples of the multilayer laminates and dual bilaminates are describedin Tables 2, 3 and 5 which provide the details of the film structure,film composition, film basis weight, nonwoven, and activation conditionsfor each example. The nonwoven used in all examples is a bicomponentPE/PP (50/50, core/sheath), 15 gsm nonwoven from Pegas Nonwovens (CzechRepublic). Examples of components used to produce multilayer laminatesare described in Table 1, and include a coextruded five layer film(example 1), extrusion bonded laminates (EBL, examples 2 and 3) and anextruded monolayer elastomer film of Vector 4211 (example 4). Thepercent recovery of strain (PRS), as measured by the PSRT method (amodified hysteresis test) is shown in Table 1 for each material using amaximum strain of 100%, 200%, 245% and 324%. The PRS results illustratehow the materials (examples 1, 2, 3, 4) respond to deformation. Vector4211 film, a highly recoverable elastomer film of SIS(styrene-isoprene-styrene block copolymer available from Dexco™ PolymersLP of Planquemine, La.), has a percent recovery of strain (PRS) of 97%to 98% for the range of maximum strains tested (100% to 324%). The 5layer coextruded film (example 1) is plastoelastic and the percentrecovery of strain (PRS) decreases as the % maximum strain of the PSRTmethod increases, with 87% PRS using 100% maximum strain, and 72% PRSusing 324% maximum strain. The EBL examples 2 and 3 have 90% PRS using100% maximum strain and 85% PRS using 324% maximum strain. Severalmultilayer laminate examples of the present invention comprise one ormore of these materials. Examples of components used to producemultilayer laminates are described in Table 7, and include extrusionbonded laminates (EBL) with coextruded five layer films (ABCBA).

TABLE 1 Examples of films and bilaminates used to construct multilayerlaminates Examples 1 2 3 4 Multilayer structure A1/B1/C/B2/A2 filmNW1/A1/B1/A2 NW1/A1/B1/A2 Vector 4211 film bilaminate bilaminateStructure reference: FIG. 7 FIG. 7 NW1¹ —  1  1 — A1 Infuse/PE blend²Infuse/PE blend Infuse/PE blend — B1 Vistamaxx 6102 VM blend³ VM blend —C: additional polymer layer Trim blend⁴ — Vector 4211 B2 Vistamaxx 6102— — A2 Infuse/PE blend Infuse/PE blend Infuse/PE blend — A1 = A2 yes yesyes — B1 = B2 yes — — — total film basis weight 25 gsm 25 gsm 15 gsm 40gsm multilayer film structure A1/B1/C1/B2/A2 A1/B/A2 A1/B/A2 monolayerNip Gap (CC) at combining Rolls⁵ — CC CC — PSRT⁶ - Modified 2 CycleHysteresis Test Percent Recovery of Strain⁷ 100% maximum strain 87 90 9097 200% maximum strain 80 90 90 98 245% maximum strain 77 88 88 97 324%maximum strain 72 85 85 97 ¹NW1 = 1 = 15 gsm (50/50 core/sheath, PP/PE)bicomponent spunbond, produced at Pegas Nonwovens (Czech Republic).²Infuse/PE blend = Infuse 9107 (25%), Elite 5800 PE (75%), in weight %,plus up to 1% Ampacet 10562 added, and optionally 1%-2% by weight ofLLDPE/TiO2/dye blend. ³VM blend = Vistamaxx 6102 (92%), Ampacet 10562(1%), Ampacet 110361 (7%) in weight %. ⁴Trim blend = Vistamaxx 6102(48%), Infuse 9107 (4%), Elite 5800 (11%), P3155 (18.5%), Aspun PE 6850A(18.5%) in weight %. ⁵Nip gap in controlled compression (CC) is the gapbetween the two combining rolls during bilaminate production and isapproximately the thickness of the materials pressed in the opening(~0.005″). Examples #2 and #3 in this table are adhesive free extrusionbonded laminates (EBL) of a ABA coextruded film and a bico nonwoven,NW1. ⁶PSRT = Percent Strain Recovery Test, a modified 2 Cycle Hysteresistest with no hold at maximum strain. ⁷Percent Recovery of Strain = 100 ×[1 − (% set/max % strain)], as measured by the PSRT modified hysteresistest

Examples of multilayer laminates with a five layer coextruded film,described in Tables 2 and 3 (examples 5 to 10) and illustrated in FIG.6B, are made by adhesive lamination of NW1 and NW2 to the A1 and A2layers of the coextruded film (A1/B1/C1/B2/A2) with 6 gsm of H2861adhesive (commercially available from Bostik Inc. of Wauwatosa, Wis.).Examples 5 to 10 have the same multilayer structure, and each example isactivated on the HSRP to a different depth of engagement (DOE), asdisclosed in Table 3. The nonwovens NW1 and NW2 in examples 5 to 10 area bicomponent PP/PE (50/50, core/sheath), 15 gsm nonwoven from PegasNonwovens (Czech Republic). The five layer coextruded film, described inTable 1 (example 1), comprises a tie layer (A1) and a skin layer (A2),where the composition of A1 is compositionally identical to A2, and is aweight % blend of 25% Infuse 9107 and 75% Elite 5800 (draw downpolymer), plus up to 1% Ampacet 10562 (process aid) and 1%-2% by weightof LLDPE/TiO2/dye blend added to the 25/75 Infuse/Elite 5800 blend. Thetwo inner layers (B1 and B2) of the five layer coextruded film compriseVistamaxx 6102 and the additional polymer layer, C1, comprises a weight% blend of 48% Vistamaxx 6102, 4% Infuse 9107, 11% Elite 5800, 18.5% PP3155, and 18.5% Aspun PE 6850A. FIG. 16 is an SEM image of the fivelayer coextruded film (example 1). Vistamaxx 6102 and PP3155 resins areavailable from ExxonMobil Chemical Company of Houston, Tex. Ampacetmaterials are available from Ampacet Corporation, Cincinnati, Ohio.Infuse 9107, Elite 5800 and Aspun PE 6850A resins are available from TheDow Chemical Company of Midland, Mich.

TABLE 2A Examples of Hand-Made Multilayer Laminates. Examples 5 11Multilayer structure NW1/A1/B1/C1/B2/A2/NW2 NW1/A1/B1/C1/B2/A2/C2/A3/B3/A4/NW2 Structure reference: FIG. 6B FIG. 14 NW1¹ 1 1 A1: Infuse/PEblend² Infuse/PE blend B1 Vista maxx 6102 Vista maxx 6102 C1 Trim blend⁴Trim blend B2 Vista maxx 6102 Vista maxx 6102 A2: Infuse/PE blendInfuse/PE blend A3 & A4: — Infuse/PE blend B3 — VM blend³ C2 — H2861adhesive NW2 1 1 A1 = A2 yes yes B1 = B2 yes yes total film basis weight(before activation) 25 gsm 50 gsm multilayer film basis weight (gsm)structure 3/7/5/7/3 3/19/3 multilayer film structure A1/B1/C1/B2/A2A1/B1/C1/B2/A2/C2/A3/B3/A4 Adhesive used in bilaminate production? — NONip Gap (CC) at combining Rolls⁵ — CC Components combined by adhesiveNW1 + film + NW2 NW + film + bilaminate lamination⁶: Details of HighSpeed Research Press (HSRP) activation⁷ simulated web speed (m/sec) 2.742.74 activation temperature 22° C. 40° C. target maximum activationstrain rate (sec⁻¹) 905 905 HSRP activation pitch, inches (mm) 0.098″(2.49 mm) 0.098″ (2.49 mm) Depth of engagement, DOE, inches (mm) 0.250″(6.35 mm) 0.250″ (6.35 mm) Average Strain of activation (%) 424% 424%Post activation Set (%)  39%  22%

TABLE 2B Examples of Hand-Made Multilayer Laminates. Examples 12 13Multilayer structure NW1/A1/B1/C1/B2/A2/C2/NW2NW1/A1/B1/A2/C1/A3/B2/A4/NW2 dual bilaminate Structure reference: FIG.15 FIG. 11 NW1¹ 1 1 A1: Infuse/PE blend Infuse/PE blend B1 Vistamaxx6102 VM blend³ C1 Trim blend H2861 adhesive B2 Vistamaxx 6102 VM blendA2: Infuse/PE blend Infuse/PE blend A3 & A4: — Infuse/PE blend B3 — — C2Vector 4211 film + — H2861 adhesive NW2 1 1 A1 = A2 yes yes B1 = B2 yesyes total film basis weight (before activation) 62 36 gsm multilayerfilm basis weight (gsm) structure 2/11/2/6/2/11/2 multilayer filmstructure A1/B1/C1/B2/A2/C2 A1/B1/A2/C1/A3/B2/A4 Adhesive used inbilaminate production? — NO Nip Gap (CC) at combining Rolls⁵ — CCComponents combined by adhesive NW + film + film + NW bilaminate +bilaminate lamination⁶: Details of High Speed Research Press (HSRP)activation⁷ simulated web speed (m/sec) 2.74 2.74 activation temperature22° C. 40° C. target maximum activation strain rate (sec⁻¹) 905 905 HSRPactivation pitch, inches (mm) 0.098″ (2.49 mm) 0.098″ (2.49 mm) Depth ofengagement, DOE, inches (mm) 0.250″ (6.35 mm) 0.250″ (6.35 mm) AverageStrain of activation (%) 424% 424% Post activation Set (%)  7%  10%

Tables 2A and 2B

-   -   1. NW1=1=15 gsm (50/50 core/sheath, PP/PE) bicomponent spunbond,        produced at Pegas Nonwovens (Czech Repub    -   2. Infuse/PE blend=Infuse 9107 (25%), Elite 5800 PE (75%), in        weight %, plus up to 1% Ampacet 10562 added, and optionally        1%-2% by weight of LLDPE/TiO₂/dye blend.    -   3. VM blend=Vistamaxx 6102 (92%), Ampacet 10562 (1%), Ampacet        110361 (7%) in weight %.    -   4. Trim blend=pre-compounded blend of Vistamaxx 6102 (48%),        Infuse 9107 (4%), Elite 5800 (11%), P3155 (18.5%), Aspun PE        6850A (18.5%) in weight %.    -   5. Nip gap in controlled compression (CC) is the gap between the        two combining rolls during bilaminate production and is        approximately the thickness of the materials pressed in the        opening (˜0.005″). Examples 11 and 13 in this table comprise    -   6. Adhesive laminate bond is designated by (+) wherein the bond        at each (+) interface is made with 6 gsm H2861 adhesive    -   7. See Table 3 for additional examples (6, 7, 8, 9, 10) with        multilayer structure of Example 5, activated to different depths        of engagement.

The multilayer laminate example 11, disclosed in Table 2A andillustrated in FIG. 14, comprises a nonwoven (NW1) adhesively bonded tothe A1 layer of five layer coextruded plastoelastic film(A1/B1/C1/B2/A2), that is adhesively combined to an extrusion bondedbilaminate (A3/B3/A4/NW2) at the A2/A3 interface with 6 gsm H2861adhesive (C2).

The multilayer laminate example 12, disclosed in Table 2B andillustrated in FIG. 15, comprises a five layer coextruded plastoelasticfilm (example 1, A1/B1/C1/B2/A2) adhesively combined to an additionalpolymer layer, C2, comprising about 25 gsm Vector 4211 film. Multilayerlaminate example 12, is hand made by adhesive lamination with 6 gsm ofH2861 adhesive of NW1 and NW2 to the A1 and C2 layers respectively ofthe combined multilayer film (A1/B1/C1/B2/A2/C2). The multilayerlaminate example 13, disclosed in Table 2B, is a dual bilaminatestructure that is hand made by adhesively laminating two extrusionbonded bilaminates (NW1/A1/B1/A2+A3/B2/A4/NW2, both example 3) with 6gsm H2861 adhesive (layer C1 of FIG. 11) at the A2 and A3 layers of theEBLs.

Examples 5 to 13 are multilayer laminates with two nonwoven that aresubjected to activation on a high speed research press (HSRP) asdescribed in U.S. Pat. Nos. 7,062,983 and 6,843,134.Activation in thedescribed simulated ring rolling process refers to using aluminum plateswith inter-meshing teeth to selectively stretch portions of the laminatesuch that the nonwoven is broken and/or elongated and the elastic filmis able to extend and retract without being unduly encumbered by thenonwoven. The laminates useful in the absorbent articles of the presentinvention may be activated with the elongation imparted in the machinedirection and or the cross direction (CD) with a target engineeringstrain of about 60% (for example with a pair of flat plates withintermeshing teeth having a depth of engagement of about 1.52 mm and apitch of about 2.49 mm) or a target engineering strain of about 187%(for example with a pair of flat plates with intermeshing teeth having adepth of engagement of about 3.30 mm and a pitch of about 2.49 mm) or atarget engineering strain of about 245% (for example with a pair of flatplates with intermeshing teeth having a depth of engagement of about4.06 mm and a pitch of about 2.49 mm) or a target engineering strain ofabout 285% (for example with a pair of flat plates with intermeshingteeth having a depth of engagement of about 4.57 mm and a pitch of about2.49 mm) or a target engineering strain of about 305% (for example witha pair of flat plates with intermeshing teeth having a depth ofengagement of about 4.83 mm and a pitch of about 2.49 mm) or a targetengineering strain of about 364% (for example with a pair of flat plateswith intermeshing teeth having a depth of engagement of about 5.59 mmand a pitch of about 2.49 mm) or a target engineering strain of about424% (for example with a pair of flat plates with intermeshing teethhaving a depth of engagement of about 6.35 mm and a pitch of about 2.49mm). The multilayer laminate examples are mechanically activated usingactivation plates having inter-meshing teeth with a tip radius of 0.1mm, a root radius of 0.5 mm and tooth height of 10.15 mm. The activationresults in the laminate having an increased level of stretch (%engineering strain at 1 N/cm force, as measured by the Tensile TestMethod) compared to the non-activated laminate. Additional details ofactivation with the HSRP are shown in Tables 2A, 2B, and 3 (activationpitch, target maximum activation strain rate, depth of engagement andaverage % engineering strain of activation). The post activation set ofa material is measured by marking the material before activation with 2pen marks, separated by a distance (L_(i)) in the direction ofactivation, followed by activating the material and measuring thedistance between the two marks after activation (L_(f)). The percentpost activation set is calculated with the equation; percent postactivation set=100*((L_(r)−L_(i))/L_(i)). For example, a sample markedwith two pen marks 80 mm apart is activated. After activation, thedistance between the two pen marks is 88 mm, and the percent postactivation set is 10% [=100%88−80)/80)]. For multilayer laminateexamples 5 to 10, comprising a 5 layer plastoelastic coextruded film(example 1), the post activation set increased from 3% to 39% (shown inTable 3) as the DOE of activation increased from 0.060″ to 0.250″, whichcorresponds to an average strain of activation of 60% to 424%. Theplastoelastic laminate (examples 5 to 10) has increased amount of postactivation set as the depth of engagement of activation increases. ThePercent Strain Recovery Test (PSRT) method is useful in predicting how amaterial will respond to high speed activation. In the case of example 1(5 layer plastoelastic coextruded film), the percent recovery of strain(PRS) decreases from 87% to 72% as the % maximum strain increases from100% to 324%.

The activated multilayer laminates are allowed to age a minimum of 1 dayat 23±2° C. before testing the physical properties. Activated multilayerlaminates examples comprising polyolefin resins in the film compositionare allowed to age a minimum of 7 days at 23±2° C. before testing thephysical properties.

TABLE 3 Multilayer Laminate Activated to various Depths of Engagement(DOE) Examples 6 7 8 9 10 5 Multilayer structure See Table 2, Example #5NW1/A1/B1/C1/B2/A2/NW2 Structure reference: FIG. 6B Details of HighSpeed Research Press (HSRP) activation¹ target maximum activation strainrate (sec⁻¹) 240 533 638 734 823 905 HSRP activation pitch, 0.098″inches = 2.49 mm 0.098″ 0.098″ 0.098″ 0.098″ 0.098″ 0.098″ Depth ofengagement, DOE, inches (mm) 0.060″ 0.130″ 0.160″ 0.190″ 0.220″ 0.250″(1.52 mm) (3.30 mm) (4.06 mm) (4.83 mm) (5.59 mm) (6.35 mm) Maximumaverage strain of activation (%) 60% 187% 245% 305% 364% 424% PostActivation SET (%)  3%  13%  22%  29%  34%  39% Pin Holes (>0.5 mmlongest dimension) none none none none none few holes ¹Laminates HSRPactivated at ambient temperature (~22 degrees °Celcius)

Examples of extrusion bonded laminates (EBL) are described in Table 1(examples 2 and 3) , and as a component of multilayer laminate examplesin Table 2 (examples 11 and 13) and in Table 5 (examples 14, 15, 16 and17). Disclosed in Table 2 and Table 5 are the components combined byadhesive lamination to make the multilayer laminate examples, theinterface(s) with adhesive, and the type and basis weight of adhesiveused. The EBL examples can be read in conjunction with FIG. 7, whichillustrates a first nonwoven (NW1), a film comprising a tie layer (A1),an inner layer (B), and a skin layer (A2). The composition of the filminner layer (B) for examples 2, 3, 11 and 13 is a weight % blend of 92%Vistamaxx 6102, 1% Ampacet 10562 (process aid) and 7% Ampacet 110361(white masterbatch with 70% TiO₂). The composition of the film innerlayer (B) of the EBL of examples 14, 15, 16, and 17 is a weight % blendof 87% Vistamaxx 6102, 5% INSPIRE Dow 118 PP (available from The DowChemical Company of Midland, Mich.), 1% Ampacet 10562 (process aid) and7% Ampacet 110361 (white masterbatch with 70% TiO₂). These are examplesof EBLs with a multilayer film (A1BA2) comprising a tie layer (A1) and askin layer (A2), where the composition of A1 is compositionallyidentical to A2, and is a weight % blend of 25% Infuse 9107 and 75%Elite 5800 (draw down polymer), and up to 1% Ampacet 10562 (processaid). The nonwoven used in all examples is a bicomponent PP/PE (50/50,core/sheath), 15 gsm nonwoven from Pegas Nonwovens (Czech Republic). Thecomposition of A1 and A2 is selected to improve the bonding of the filmto the bicomponent (PP/PE, core/sheath) nonwoven in order to reduce theoccurrence of delamination, to prevent blocking of the film surface tothe nonwoven in a roll of bilaminate, and to improve the activationsurvivability of the extrusion laminate (for example, to minimize oreliminate the formation of unwanted pin holes during activation). Animportant component of the EBL is the nonwoven and a desirable propertyof the nonwoven is high extensibility. One desirable property of ahighly extensible nonwoven for use in extrusion bonded laminates (EBL)is that the HSRP activated nonwoven (for example, activated to a targetengineering strain of about 245% with a pair of flat plates withintermeshing teeth having a depth of engagement of about 4.06 mm and apitch of about 2.49 mm) has a tensile strength very similar to thenon-activated nonwoven (i.e. no large loss in tensile strength due toactivation).

The extrusion bonded bilaminate examples shown in Tables 1, 2, and 5 areadhesive free and are produced with controlled compression (CC), whichis a specified gap between the combining rolls.

Multilayer laminate examples 5, 11, 12 and 13 are all activated deeplyon the HSRP to 0.250″ DOE (2.49 mm pitch), as shown in Table 2. The postactivation set of these examples (also shown in Table 2) illustrate howdifferent combinations of materials with different PRS (shown inTable 1) can result in a range of post activation set (7% to 39%).Example 12 has very low post activation set (7%), and has a multilayerfilm that is a plastoelastic film combined with a highly recoverablefilm (Vector 4211). In contrast, example 5, a laminate with onlyplastoelastic film, has a higher post activation set (39%).Incorporating both of these laminates in an absorbent article, allowsfor the creation of gathered materials. For example, as disclosedearlier, a strip of high-recovery film laminate may be applied over aportion of a base plastoelastic bilaminate that exhibits some largermeasurable amount of permanent set. When the combination is subjected toa primary deformation cycle as the one produced by mechanicalactivation, regions can be created of gathered materials within the basebilaminate adjacent to the high-recovery dual bilaminate due to thepermanent shaping of these adjacent regions and the differential instrain and recovery. The amount of gathering can be controlled by theactivation depth of engagement, as shown in table 3 for theplastoelastic examples 5 to 10, and also by the selection of materialscombined, as shown in Table 2. Example 11, is a combination of aplastoelastic film and a EBL and has a post activation set of 22%.Example 13, a dual bilaminate (combination of two EBLs), has a postactivation set of 10%.

The physical properties of the multilayer laminate examples 5, 9, 10,11, 12, and 13 are shown in Table 4. Examples 5, 9 and 10 (laminate withplastoelastic film) have a basis weight of about 50 gsm and an ultimatetensile strength of 4.0 N/cm to 5.3 N/cm. The stretch (% engineeringstrain at 1 N/cm) for multilayer laminate examples 9, 10 and 5 are 83%,105% and 120% respectively, which shows an increase in stretch as theDOE of activation increases (0.190″, 0.220″ and 0.250″ DOErespectively). Hysteresis results (cycle 1 with 130% engineering strain)for multilayer laminate examples 9, 10 and 5 shows a decrease in % setand an increase in unload forces as the DOE of activation increases, andhave cycle 1 unload forces at 50% strain of 0.07 N/cm to 0.09 N/cm,percent set of 12% to 16%, and force relaxation of 38% to 40%. Example11 (74 gsm laminates with plastoelastic film+EBL) and example 12 (89 gsmlaminate with plastoelastic film+Vector 4211 film) have higher tensilestrength (5.9 N/cm and 6.3 N/cm) and better elastic properties thanlaminates with only plastoelastic film (examples 5, 9, 10), wherein theformer have a lower percent set (approximately 7% to 10%), a lower forcerelaxation (34% and 30%), and higher unload forces at 50% engineeringstrain (0.15 N/cm and 0.17 N/cm). The stretch for multilayer laminateexamples 11 and 12 are 84% and 125% (% engineering strain at 1 N/cm).The dual bilaminate example 13 (60 gsm) has an ultimate tensile strengthof 4.2 N/cm, low hysteresis percent set (8.1%) and force relaxation(30%), and an unload force at 50% engineering strain of 0.16 N/cm. It isinteresting to note that the elastic properties of the dual bilaminate(example 13) are very similar to multilayer laminate example 12 (withplastoelastic film+Vector 4211 film) at approximately two thirds of thebasis weight (60 gsm vs. 89 gsm), while the tensile strength is lower(4.2 N/cm vs. 6.3 N/cm). The low load forces of the dual bilaminate (0.8N/cm at 130% strain) may improve the ease of application of an absorbentarticle when used as a waist feature, side panel or back ear laminate.Dual bilaminate example 13 has a higher level of stretch (215%engineering strain at 1 N/cm) compared to the other examples.

TABLE 4 Physical properties of multilayer laminate examples 5, 9, 10,11, 12, 13 (2 Cycle Hysteresis and Tensile test) Examples 9 10 5 11 1213 basis weight (gsm) 51 49 47 74 89 60 2 Cycle Hysteresis Results (130%engineering strain, C1 = Cycle 1) C1 Load force at 130% strain (N/cm)2.11 1.47 1.25 1.42 1.09 0.81 C1 Unload force at 50% strain (N/cm) 0.070.08 0.09 0.15 0.17 0.16 C1 Unload force at 30% strain (N/cm) 0.01 0.020.03 0.06 0.07 0.09 % SET (% strain) 15.9 12.8 11.5 9.8 6.9 8.1 ForceRelaxation (%) 39.5 38.2 38.5 34 29.8 29.7 Tensile Test Results Stretchat 1 N/cm (% engineering strain) 83 105 120 84 125 215 Ultimate tensilestrength (N/cm) 5.3 4.0 4.1 5.9 6.3 4.2 Strain at break (% engineeringstrain) 502 406 387 547 640 681 % RSD for strain @ break 12 25 75 45 2022

Examples 14, 15, 16, and 17 are made by a high speed lamination andactivation process. In examples 14 and 15, the aged roll of extrusionbilaminate with 20 gsm A1/B1/A2 film is combined with a second nonwoven(e.g., NW2) using an adhesive lamination process, with the addition ofapproximately 4.5 gsm of Bostik H2861 adhesive to the A2 film-NW2interface, followed by mechanically activation by a ring rollingactivation process at a line speed of about 6.1 meter per second, toform a trilaminate (activation details are shown in Tables 5A and 5B).

In examples 16 and 17, the aged roll of extrusion bilaminate with 10 gsmfilm (NW1/A1/B1/A2) is combined with a second aged roll of extrusionbilaminate with 10 gsm film (A3/B2/A4/NW2) using an adhesive laminationprocess, with the addition of approximately 4.5 gsm of Bostik H2861adhesive to the interface between the outer film layer of eachbilaminate ((A2-A3 of FIG. 11), followed by mechanically activation by aring rolling activation process at a line speed of about 6.1 meter persecond, to form a dual bilaminate (activation details are shown inTables 5A and 5B).

TABLE 5A Examples of Line Made Multilayer Laminates Examples 14 15Multilayer Structure NW1/A1/B1/A2/ NW1/A1/B1/A2/ NW2 NW2 Structurereference: EBL⁵ FIG. 6A EBL⁵ FIG. 6A NW1¹ 1 1 A1 and A2: Infuse/PEblend² Infuse/PE blend B1 and B2 VM blend³ VM blend C1 — — A3 and A4: —— NW2 1 1 A1 = A2 = A3 = A4 — — total film basis weight (excluding 20gsm 20 gsm adhesive) multilayer film structure A1/B1/A2 A1/B1/A2Adhesive used in bilaminate? NO NO Nip Gap (CC) at combining Rolls⁴ CCCC Details of On-line High Speed adhesive lamination and activationComponents combined by bilaminate + NW bilaminate + NW adhesivelamination Interface with Adhesive A2-NW2 A2-NW2 Adhesive type (Bostik)H2861 H2861 Adhesive basis weight (gsm) 4.5 gsm 4.5 gsm Nip Gap 0.005″0.005″ line speed (m/sec) 6.13 6.13 activation pitch (inches) 0.100″0.100″ Depth of engagement, DOE, 0.160″ (4.06 mm) 0.180″ (4.57 mm)inches (mm) Average Strain of activation (%) 240% 279% ¹NW1 = 1 = 15 gsm(50/50 core/sheath, PP/PE) bicomponent spunbond, produced at PegasNonwovens (Czech Republic). ²Infuse/PE blend = Infuse 9107 (25%), Elite5800 PE (75%), in weight %, plus up to 1% Ampacet 10562 added. ³VM blend= Vistamaxx 6102 (87%), Dow 118 PP (5%), Ampacet 10562 (1%), Ampacet110361 (7%) in weight %. ⁴Nip gap in controlled compression (CC) is thegap between the two combining rolls during bilaminate production and isapproximately the thickness of the materials pressed in the opening(~0.005″). All examples in this table are made using extrusion bondedlaminates (EBL) with an ABA coextruded film and a bico nonwoven, NW1.⁵EBL, FIG. 6A from Application No. 12/358,962, filed Jan. 23, 2009EXTRUSION BONDED LAMINATES FOR ABSORBENT ARTICLES.

TABLE 5B Examples of Line Made Multilayer Laminates Examples 16 17Multilayer Structure NW1/A1/B1/A2/C1/A3/B2/A4/NW2NW1/A1/B1/A2/C1/A3/B2/A4/NW2 Structure reference: FIG. 11 FIG. 11 NW1¹ 11 A1 and A2: Infuse/PE blend Infuse/PE blend B1 and B2 VM blend VM blendC1 H2861 adhesive H2861 adhesive A3 and A4: Infuse/PE blend Infuse/PEblend NW2 1 1 A1 = A2 = A3 = A4 yes yes total film basis weight(excluding 20 gsm 20 gsm adhesive) multilayer film structureA1/B1/A2/C/A3/B2/A4 A1/B1/A2/C/A3/B2/A4 Adhesive used in bilaminate? NONO Nip Gap (CC) at combining Rolls⁴ CC CC Details of On-line High Speedadhesive lamination and activation Components combined by bilaminate +bilaminate = bilaminate + bilaminate = adhesive lamination dualbilaminate dual bilaminate Interface with Adhesive A2/A3 A2/A3 Adhesivetype (Bostik) H2861 H2861 Adhesive basis weight (gsm) 4.5 gsm 4.5 gsmNip Gap 0.005″ 0.005″ line speed (m/sec) 6.13 6.13 activation pitch(inches) 0.100″ 0.100″ Depth of engagement, DOE, 0.160″ (4.06 mm) 0.180″(4.57 mm) inches (mm) Average Strain of activation (%) 240% 279% ¹NW1 =1 = 15 gsm (50/50 core/sheath, PP/PE) bicomponent spunbond, produced atPegas Nonwovens (Czech Republic). ²Infuse/PE blend = Infuse 9107 (25%),Elite 5800 PE (75%), in weight %, plus up to 1% Ampacet 10562 added. ³VMblend = Vistamaxx 6102 (87%), Dow 118 PP (5%), Ampacet 10562 (1%),Ampacet 110361 (7%) in weight %. ⁴Nip gap in controlled compression (CC)is the gap between the two combining rolls during bilaminate productionand is approximately the thickness of the materials pressed in theopening (~0.005″). All examples in this table are made using extrusionbonded laminates (EBL) with an ABA coextruded film and a bico nonwoven,NW1. ⁵EBL, FIG. 6A from Application No. 12/358,962, filed Jan. 23, 2009;EXTRUSION BONDED LAMINATES FOR ABSORBENT ARTICLES.

The EBLs of said examples are allowed to age a minimum of 1 day at 23±2°C. after fabrication before the adhesive lamination process to producethe trilaminates or the dual bilaminates. The activated trilaminate anddual bilaminate samples are allowed to age a minimum of 7 days at 23±2°C. before testing the physical properties (for example, the tensile testand the two cycle hysteresis test).

The physical properties of the activated trilaminates (examples 14 and15) and dual bilaminates (examples 16 and 17) are shown in Tables 6A and6B. The results enable comparison of multilayer laminates with the samebasis weight of film (˜20 gsm, excluding adhesive) and different numbersof layers of film (3 vs. 6, plus one additional layer of adhesive) andillustrate how the extra layers of film impact the physical propertiesincluding hysteresis, tensile strength and occurrence of pin holes. Thelargest impact is observed for the % engineering strain at break, whereit is significantly higher for the dual bilaminate, compared to thetrilaminate (594% vs 439% after activation to 0.160″ DOE and 567% vs.375% after activation to 0.180″ DOE). Finally, the results alsodemonstrate that increasing the activation DOE from 0.160″ DOE to 0.180″DOE (at 0.100″ pitch) can impact the properties of the laminates. Themore deeply activated trilaminate (examples 15 activated at 0.180″ DOE)has lower tensile strength, lower % engineering strain at break, lowerpermanent set, lower load forces and an increase in the number of pinholes observed compared to example 14 activated at 0.160″ DOE. Deeperactivation also creates laminates with higher stretch (% engineeringstrain at 1 N/cm). Multilayer laminate examples 14 and 16, activated to0.160″ DOE, have 115% and 116% stretch, while multilayer laminateexamples 15 and 17, activated to 0.180″ DOE, have 141% and 144% stretch.

TABLE 6A Physical properties of line activated multilayer laminateexamples 14 and 15 Examples 14 15 Depth of engagement (DOE) inches0.160″ 0.180″ basis weight (gsm) 50 49 2 Cycle Hysteresis Results (130%engineering strain, C1 = Cycle 1) C1 Load force at 130% strain (N/cm)1.80 1.23 C1 Unload force at 50% strain (N/cm) 0.09 0.09 C1 Unload forceat 30% strain (N/cm) 0.03 0.03 % SET (% strain) 14.2 12.8 ForceRelaxation (%) 39.9 39.4 Tensile Test Results Stretch at 1 N/cm (%engineering strain) 115 141 Ultimate tensile strength (N/cm) 3.1 2.8Strain at break (% engineering strain) 439 375 Range of strain at break(% min-max) 284-627 282-552 % RSD for strain @ break 115 98 Pin HoleEvaluation¹ (catargorized by the longest dimension of the hole or tear)small (>0.5 mm and <1 mm) 24 421 medium (>1 mm and <2 mm) 4 31 large (>2mm and <3 mm) 0 0 extra large (>3 mm) 0 0 ¹Number of pin holes (pinholes/m²) is calculated from the evaluation of n = 20 activated samples,each 100 mm × 127 mm.

TABLE 6B Physical properties of line activated multilayer laminateexamples 16 and 17 Examples 16 17 Depth of engagement (DOE) inches0.160″ 0.180″ basis weight (gsm) 49 50 2 Cycle Hysteresis Results (130%engineering strain, C1 = Cycle 1) C1 Load force at 130% strain (N/cm)1.67 1.07 C1 Unload force at 50% strain (N/cm) 0.08 0.09 C1 Unload forceat 30% strain (N/cm) 0.03 0.03 % SET (% strain) 15.7 14.0 ForceRelaxation (%) 39.4 37.0 Tensile Test Results Stretch at 1 N/cm (%engineering strain) 116 144 Ultimate tensile strength (N/cm) 2.7 2.4Strain at break (% engineering strain) 594 567 Range of strain at break(% min-max) 539-627 482-608 % RSD for strain @ break 30 43 Pin HoleEvaluation¹ (catargorized by the longest dimension of the hole or tear)small (>0.5 mm and <1 mm) 0 28 medium (>1 mm and <2 mm) 0 0 large (>2 mmand <3 mm) 0 0 extra large (>3 mm) 0 0 ¹Number of pin holes (pinholes/m²) is calculated from the evaluation of n = 20 activated samples,each 100 mm × 127 mm.

In the case of the dual bilaminates, the increase in activation DOE(0.160″ vs. 0.180″, examples 16 and 17), does not result in asignificant drop in the % engineering strain at break and the pin holeobservations are low for both examples (no holes observed>1 mm). Theseresults support the theory that laminates with more layers of film haveimproved toughness and activation survivability. Example 17 (activatedto 0.180″ DOE) also has lower load forces, lower permanent set, lowerforce relaxation and similar unload forces compared to Example 16(activated to 0.160″ DOE), which can enable improved application andfit.

Additional examples of components used to produce multilayer laminatesare described in Tables 7A and 7B, and include extrusion bondedlaminates (EBL) with coextruded five layer films (ABCBA). Example 1, aplastoelastic coextruded five layer film from Table 1, is also included.Example 18, 19 and 20 are EBL comprising a 5 layer multilayer film witha tie layer (A1), two inner layers (B1 and B2), an additional polymerlayer (C1) and a skin layer (A2), extrusion laminated to an 18 gsm Pegasbico nonwoven (NW1). The composition of the film outer layers (A1 andA2) for examples 18, 19 and 20 is a weight % blend of 75% Elite linearlow density polyethylene, 25% Infuse 9107, plus 1% Ampacet 10562(process aid) and 0.1% Irgonox 1010. Example 18 has two inner layers (B1and B2) comprising 93% Vistamaxx 6102FL and 7% Ampacet 110359 (whitemaster batch with TiO2), and the additional polymer layer (C1)comprising Vistamaxx 6102FL. Example 19 has two inner layers (B1 and B2)comprising Vistamaxx 6102FL and the additional polymer layer (C1)comprising Septon F4911 (SEEPS based elastomer blend). Example 20 hastwo inner layers (B1 and B2) comprising Vistamaxx 6102FL and theadditional polymer layer (C1) comprising 96% Septon 2004 (SEPSelastomer, available from Kuraray America, Inc, Houston, Tex.) and 4%Ampacet 110359 (white master batch with TiO₂).

The percent recovery of strain (PRS), as measured by the PSRT method (amodified hysteresis test) is shown in Tables 7A and 7B for each materialusing a maximum strain of 100%, 245% and 324%. The PRS resultsillustrate how the materials (examples 1, 18, 19 and 20) respond todeformation. For the 5 layer plastoelastic coextruded film (example 1),the percent recovery of strain (PRS) decreases as the % maximum strainof the PSRT method increases, with 87% PRS using 100% maximum strain,and 72% PRS using 324% maximum strain. The EBL example 18, withVistamaxx 6102 B/C/B layers, has 90% PRS using 245% maximum strain and87% PRS using 324% maximum strain. The EBL examples comprising an SBC inthe C layer, example 19 (SEEPS C layer) and example 20 (SEPS C layer),have >94% PRS using 245% maximum strain and 324% maximum strain anddemonstrate a high level of elastic recovery. A dual bilaminate made bycombining an EBL with high PRS (example 19 or 20) to a portion of thearea of a plastoelastic film or EBL with lower PRS (example 1), followedby activation will result in a gathered laminate in the region where theplastoelastic laminate is adjacent to the combined dual bilaminate,which could be used, for example, as stretch outer cover with awaistband.

TABLE 7A Examples of extrusion bonded laminates (EBL) comprising 5 layerMultilayer film Examples 1 18 Multilayer Structure A1/B1/C/B2/A2NW1/A1/B1/C1/B2/A2 film Structure reference: film bilaminate; FIG. 8NW1¹ — 1 A1 and A2: Infuse/PE blend² Infuse/PE blend B1 and B2 Vistamaxx6102 VM blend³ C1 Trim blend⁴ VM blend³ B1:C1:B2 feedblock ratio20-60-20 NW2 — 0 A1 = A2 yes yes total film basis weight (excludingadhesive) ~25 gsm ~27 gsm multilayer film structure A1/B1/C1/B2/A2A1/B1/C1/B2/A2 Adhesive used in bilaminate? — NO Tensile Test Results —Basis weight (gsm) — 44 Stretch at 1 N/cm (% engineering strain) —  18%Ultimate tensile strength (N/cm) — 3.60 std. dev n = 10 — 0.51 Strain atbreak (% engineering strain) — 675% — 1.77 Mode 2 Peel (N/cm) — 1.8PSRT⁵ - Modified 2 Cycle Hysteresis Test Percent Recovery of Strain⁶100% maximum strain 87 92 245% maximum strain 77 90 324% maximum strain72 87 ¹NW1 = 1 = ~18 gsm (50/50 core/sheath, PP/PE) bicomponentspunbond, produced at Pegas Nonwovens (Czech Republic). ²Infuse/PE blend= Infuse 9107 (25%), Elite LLD PE (75%), in weight %, plus up to 1%Ampacet 10562 added. ³VM blend = Vistamaxx 6102FL plus up to 7% Ampacet110359 in weight %. ⁴Trim blend = Vistamaxx 6102 (48%), Infuse 9107(4%), Elite 5800 (11%), P3155 (18.5%), Aspun PE 6850A (18.5%) in weight%. ⁵Examples 18, 19 and 20 are made using extrusion bonded laminates(EBL) with an ABCBA coextruded film and a bico nonwoven, ⁶PSRT = PercentStrain Recovery Test, a modified 2 Cycle Hysteresis test with no hold atmaximum strain. ⁷Percent Recovery of Strain = 100 × [1 − (% set/max %strain)], as measured by the PSRT modified hysteresis test

TABLE 7B Examples of extrusion bonded laminates (EBL) comprising 5 layerMultilayer film Examples 19 20 Multilayer Structure NW1/A1/B1/C1/B2/A2NW1/A1/B1/C1/B2/A2 Structure reference: bilaminate; FIG. 8 bilaminate;FIG. 8 NW1¹ 1 1 A1 and A2: Infuse/PE blend Infuse/PE blend B1 and B2 VMblend VM blend C1 Septon F4911 (SEEPS) Septon 2004 (SEPS) B1:C1:B2feedblock ratio 20-60-20 20-60-20 NW2 0 0 A1 = A2 yes yes total filmbasis weight (excluding adhesive) ~30 gsm ~30 gsm multilayer filmstructure A1/B1/C1/B2/A2 A1/B1/C1/B2/A2 Adhesive used in bilaminate? NONO Tensile Test Results Basis weight (gsm) 50 47 Stretch at 1 N/cm (%engineering strain)  19%  20% Ultimate tensile strength (N/cm) 4.39 3.37std. dev n = 10 0.95 0.32 Strain at break (% engineering strain) 506%460% 1.77 1.87 Mode 2 Peel (N/cm) 1.8 1.9 PSRT⁵ - Modified 2 CycleHysteresis Test Percent Recovery of Strain⁶ 100% maximum strain 93 94245% maximum strain 94 95 324% maximum strain 94 95 ¹NW1 = 1 = ~18 gsm(50/50 core/sheath, PP/PE) bicomponent spunbond, produced at PegasNonwovens (Czech Republic). ²Infuse/PE blend = Infuse 9107 (25%), EliteLLD PE (75%), in weight %, plus up to 1% Ampacet 10562 added. ³VM blend= Vistamaxx 6102FL plus up to 7% Ampacet 110359 in weight %. ⁴Trim blend= Vistamaxx 6102 (48%), Infuse 9107 (4%), Elite 5800 (11%), P3155(18.5%), Aspun PE 6850A (18.5%) in weight %. ⁵Examples 18, 19 and 20 aremade using extrusion bonded laminates (EBL) with an ABCBA coextrudedfilm and a bico nonwoven, ⁶PSRT = Percent Strain Recovery Test, amodified 2 Cycle Hysteresis test with no hold at maximum strain.⁷Percent Recovery of Strain = 100 × [1 − (% set/max % strain)], asmeasured by the PSRT modified hysteresis test

The examples in Tables 7A and 7B further illustrate the elastomercontent of the bilaminates may be selected from a group a variety ofelastomer resins, including, but not limited to plastoelastic polymers,polyolefin elastomers, styrene block copolymers, or combinationsthereof, to taylor the desired appearance (gathered or not) and elasticproperties of the resulting dual bilaminate.

Test Methods

Fusion Index

The fusion index is determined by the measurement specified by ASTMD3418 -08 “Standard Test Method for Transition Temperatures andEnthalpies of Fusion and Crystallization of Polymers by DifferentialScanning Calorimetry.” To determine a material's fusion index, thematerial's enthalpy of fusion, expressed in Joules/gram as measuredaccording to ASTM D3418, shall be divided by 208 J/g. For example, thefusion index of a polypropylene with an experimentally determinedenthalpy of fusion of 100 J/g is calculated as ((100/208)*100%)=48.1%.Another example: the fusion index of a PE with an experimentallydetermined enthalpy of fusion of 30 J/g is calculated as((30/208)*100%)=14.4%

DSC

Differential Scanning Calorimetry (DSC) measurements are performedaccording to ASTM D 3418, where DSC samples are prepared by firstcompression molding a polymer composition into a thin film of around0.003 inches at about 140° C. between teflon sheets. The film isannealed overnight in a vacuum oven, with vacuum drawn, at a temperatureof about 65° C. Samples are punched out of the resulting films using a 6millimeter diameter skin biopsy punch. The samples are massed toapproximately 5-10 milligrams, loaded into small aluminum pans with lids(Perkin Elmer #0219-0041), and crimped using a Perkin Elmer StandardSample Pan Crimper Press (#0219-0048). Thermal tests and subsequentanalyses are performed using a Perkin Elmer DSC 7 equipped with PerkinElmer Thermal Analyses Software version 4.00.

The melting temperature of a film composition is determined by firstheating the DSC sample from about 25° C. to 180° C. at a rate of 20° C.per minute and holding the sample at 180° C. for 3 minutes. The sampleis then quenched to minus 60° C. at a rate of 300° C. per minute, heldfor 3 minutes at minus 60° C., then heated at a rate of 20° C. perminute to 180° C. The melting temperature is taken as the temperature ofthe melting endotherm's peak. If more than one melting endotherm ispresent, the endotherm occurring at the highest temperature is used. Ifno melting peak is present in the second heat but there is one in thefirst heat (which can happen for film compositions that crystallize veryslowly), the sample pan is removed from the DSC, allowed to remain ataround 25° C. for 24 hours, reheated in the DSC from about 25° C. to180° C. at a rate of 20° C. per minute, and then the melting temperatureis taken as the highest peak temperature in this third heat.

The rate of crystallization of a film composition at a crystallizationtemperature of 20 degrees Celcius below its melting temperature isdetermined by first heating the DSC sample to the desired settemperature (which is above the melting temperature of the film),holding the sample at the set temperature for 2 minutes, and thensubjecting the sample to a rapid cooling down to the desiredcrystallization temperature (about 300° C. per minute). As thetemperature is held steady at the crystallization temperature, thecrystallization process is evidenced by the appearance of acrystallization exotherm in the DSC isothermal scan as a function oftime. A single-point characterization of the crystallization rateconsists of reporting the time at which the minimum in the exothermoccurs. The latter is often considered by those skilled in the art as areasonable indication of the half-time crystallization (t½) for thematerial.

One skilled in the art may use this method to determine thecrystallization rate of a film sample taken from, for example, a punchtaken from an absorbent article component (e.g., an outer cover)comprising an EBL (of course one should take care to first remove anyundesired components before making the punch). In this case, additionalcrystallization peaks may be observed due to the presence of additionalcomponents (e.g., nonwoven fibers) but in many cases, these are readilyassigned and do not interfere with the crystallization ratedetermination of the film or film layer of interest.

Blocking Force

All of the steps for this measurement are carried out in a roommaintained at a temperature of 23° C. ±2° C. and a relative humidity of50% ±5%.

Materials and apparati (all of the following must be located in the sameroom)

For preparing specimens with edges free from defects, notches, nicks,etc.:

knife equipped with a sharp #11 Xacto-knife blade or similar

a steel straight edge is used as a guide for the knife

office-grade printer/photocopier paper to sandwich material duringcutting

For conditioning samples

suitable tray or shelf that allows the samples to be kept reasonablyfree of contaminants such as dust, aerosols, etc.

For the application of pressure

laboratory oven set at 46C (Despach LAC or equivalent) with bafflesopen.

suitable weights and flat, rigid plates to apply a compressive pressureof 0.686 MPa to the samples.

For the T-Peel tensile test

MTS Alliance RT/1 or a machine of similar capability, equipped withgrips that provide a well-defined area of contact along a single narrowband; and the grips hold the sample along an axis perpendicular to thedirection of testing stress, the grips conforming to the descriptiongiven in ASTM D882.

Strips of an absorbent article component comprising an EBL (“material”for this method)150 mm×25.4 mm (along the material's machine andtransverse directions respectively) are prepared by sandwiching thematerial between sheets of paper and cutting with a straight-edge and asharp #11 Xacto-knife blade or similar. Shorter specimens may be used ifmaterial availability precludes specimens 150 mm in length.

1. Pre-condition the material at a temperature of 23° C. ±2° C. and arelative humidity of 50% ±5% for at least 24 hours.

2. Stack 5 samples directly on top of each other with edges aligned suchthat body-facing nonwoven side on each sample is facing upwards. Eachsample in the stack should all be consistently aligned in the MD or CD.

3. Subject one or more stacks of five strips to a compressive load of0.686 MPa in the lab oven at a temperature of 46° C. ±2° C. for 100hours ±1 hour. Leave several millimeters at the end of the stripsuncompressed to facilitate subsequent mounting in the tensile testergrips.

4. Remove pressure from specimens.

5. Remove specimens from oven and allow to equilibrate at a temperatureof 23° C. ±2° C. and a relative humidity of 50% ±5% for 45 minutes ±15minutes.

6. Testing one interface at a time, mount the stack in the tensiletester grips in a T-Peel configuration and run crosshead at a speed of2.12 mm/s (5 inches per minute) for a distance of 100 mm or, in the caseof specimens shorter than 150 mm, until the respective pieces separatecompletely. Use a data acquisition technique that provides a reliableindicator of the maximum force encountered during the peel test.

The maximum force required during the separation of two strips isrecorded as the blocking force, reported as Newtons force per cm widthof film strip. The average of at least five maximum forces is reportedas the material's blocking force. If the strips are so weakly adhered asto separate under their own weight or during mounting, then the blockingforce should be taken as zero.

Tensile Test (Mode II Failure Force)

This method is used to determine the force versus engineering straincurve of multilayer laminates, including extrusion bonded laminates(EBL). The tensile properties of the materials were measured accordingto ASTM Method D882-02 with the specifications described below. Themeasurement is carried out at a constant cross-head speed of 50.8 cm/minat a temperature of 23° C. ±2° C. The relationship between the stretchlength and the engineering tensile engineering strain γ_(tensile) isgiven by the following equation:

$\begin{matrix}{{\frac{L}{L_{o}} - 1} = \frac{\gamma_{tensile}}{100}} & \lbrack 1\rbrack\end{matrix}$

where L₀ is the original length, L is the stretched length andγ_(tensile) is in units of percent. For example, when a sample withinitial gauge length of 5.08 cm is stretched to 10.16 cm, the elongationis 100% engineering strain [((10.16/5.08)-1)*100=100% engineeringstrain] and when a sample with initial gauge length of 5.08 cm isstretched to 35.6 cm, the elongation is 600% engineering strain[((35.6/5.08)−1)*100=600% engineering strain]. The material to be testedis cut into a substantially rectilinear shape. Sample dimensions areselected to achieve the required engineering strain with forcesappropriate for the instrument. Suitable instruments for this testinclude tensile testers commercially available from MTS Systems Corp.,Eden Prairie, Minn. (e.g. Alliance RT/1 or Sintech 1/S) or from InstronEngineering Corp., Canton, Mass. For either the Alliance RT/1 or Sintech1/S instruments listed above, suitable sample dimensions areapproximately 25.4 mm wide by approximately 100 mm long. Shorterspecimens may be used, however, if material availability precludesspecimens 100 mm in length. (within the limitations outlined below).

The following procedure illustrates the measurement when using the abovesample dimensions and either an Alliance RT/1 or Sintech 1/S. Theinstrument is interfaced with a computer. TestWorks 4™ software controlsthe testing parameters, performs data acquisition and calculation, andprovides graphs and data reports.

The grips used for the test are wider than the elastic member. Typically2.00 inch (5.08 cm) wide grips are used. The grips are air actuatedgrips designed to concentrate the entire gripping force along an area ofcontact; and the grips hold the sample along an axis perpendicular tothe direction of testing stress, the grip face set in the upper andlower grips having one flat surface and an opposing face with a 6 mmline contact (half round protrusion) to minimize slippage of the sample.The load cell is selected so that the forces measured will be between10% and 90% of the capacity of the load cell or the force range used.Typically a 100 N load cell is used. The fixtures and grips areinstalled. The instrument is calibrated according to the manufacturer'sinstructions. The distance from the center of the half round of theupper grip face to the center of the half round of the lower grip face(gauge length) is 2.00 inches (50.8 mm), which is measured with a steelruler held beside the grips. The force reading on the instrument iszeroed to account for the mass of the fixture and grips. The instrumentis located in a temperature-controlled room for measurements performedat 23° C. ±2° C. The sample is equilibrated a minimum of 1 hour at 23°C. ±2° C. before testing. The mass and dimensions of the specimen aremeasured before testing and are used to calculate the basis weight ofthe specimen in grams per square meter (gsm). The specimen is mountedinto the grips in a manner such that the longitudinal axis of the sampleis substantially parallel to the gauge length direction, there is noslack and the force measured is approximately 0.01N. The sample isdeformed at a constant crosshead speed of 20 inches/min. (50.8 cm/min)to about 1000% engineering strain or until the sample breaks or exhibitsa more than nominal loss of mechanical integrity. The force, time anddisplacement are measured during the tensile test at a data acquisitionfrequency of 50 Hz. A minimum of five samples is used to determine theaverage test values. For different sample dimensions, the crossheadspeed is adjusted to maintain the appropriate engineering strain ratefor the test. For example, a crosshead speed of 10 inches /min (25.4cm/min) would be used for a sample gauge length of 1.00 inch (25.4 mm).=

For extrusion bonded laminates that exhibit a yield drop, such as shownin FIG. 5A, the yield point identifies the % engineering strain afterwhich the force decreases (or does not increase) with increasingelongation, and is usually caused by localized breaking of the nonwovenfibers and/or the onset of delamination of the nonwoven fibers from theelastomeric film. The post yield force region may reach a minimum orplateau. In some examples, the post yield force plateau region isfollowed by the sample breaking (see for example, FIG. 5B). In otherexamples the post yield force plateau region is followed by an increasein force with increasing elongation and ultimately the sample breaks(see for example, FIG. 5A). The post yield plateau force region of theextrusion bonded laminate tensile curve is used to measure the Mode II(sliding or in-plane shear mode) failure force; and the post yieldplateau force region of the extrusion bonded laminate tensile curve isused as an indicator of the extrusion laminate bond strength. The ModeII failure force is reported in N/cm and is the average force in thepost yield minimum or plateau force region, the region being selectedsuch that the percent relative standard deviation of the average (% RSD)is less than 10%. The Mode II failure is described by Richard W.Hertzberg in Deformation and Fracture Mechanics of EngineeringMaterials, 2^(nd) edition, John Wiley & Sons, New York (1976, 1983),page 276.

The tensile test results are reported for each example as one or acombination of the following properties; the percent engineering strainat 1 N/cm force (the elongation at 1 N/cm), the Mode II failure force inN/cm, the percent engineering strain at break, and the ultimate tensilestrength in N/cm (i.e., the peak force divided by the sample width, forexample, at the “break” in FIG. 5A and at the “yield point” in FIG.5B,). A minimum of five samples is used to determine the average testvalues. The percent engineering strain at 1 N/cm force is reported as ameasure of how much the laminate can stretch at low forces.

Typical Mode II failure values for well bonded laminates used inabsorbent articles of the present invention are from about 1.1 N/cm toabout 3.5 N/cm for activated samples.

In some cases, it may not be possible to measure the Mode II failureforce of the laminate, for example in cases where the sample breaksbefore the Mode II failure starts. If it is not possible to measure theMode II failure force, the laminate bond strength can be measured by theT-Peel Test (Mode I) as follows:

T-Peel (Mode I) Test

The Mode I T-peel tensile test method is performed at room temperature(23° C. ±2° C.). The material to be tested is cut into a substantiallyrectilinear shape. Sample dimensions are to be selected to achieve therequired strain with forces appropriate for the instrument. Suitablesample dimensions are approximately 25.4 mm wide by approximately 100 mmlong. Shorter specimens may be used, however, if material availabilityprecludes specimens 100 mm in length. The length of the sample is thedirection perpendicular to the axis of stretch. Suitable instruments,grips, grip faces, software for data acquisition, calculations, reports,and definition of percent strain are described in the Tensile Test (ModeII) method section above.

The load cell is selected so that the forces measured fall between 10%and 90% of the capacity of the load cell or the force range used.Typically a 25 N load cell is used. The fixtures and grips areinstalled. The instrument is calibrated according to the manufacturer'sinstructions. The distance between the lines of gripping force (gaugelength as described in Tensile Test -Mode II) is 2.54 cm, which ismeasured with a steel ruler held beside the grips. The force reading onthe instrument is zeroed to account for the mass of the fixture andgrips. The samples are equilibrated at 23° C. ±2° C. for a minimum ofone hour before testing. The mass, length and width of the specimen aremeasured before sample preparation for the T-peel test and are used tocalculate the basis weight of the specimen in grams per square meter(gsm). The samples (approximately 25.4 mm wide by approximately 100 mmlong) are prepared for T-peel test using the following procedure: (1)Mark the sample with a pen, making a line across the 2.54 cm width ofthe sample at a location 2.54 cm from the end of the sample. (2) Stretchthe sample in small increments in the 6.45 cm² area between the pen markand the end of the sample to initiate delamination of the nonwovenfibers from the film. (3) Secure a piece of masking tape (CorporateExpress, MFG# CEB1X6OTN, from Paperworks, Inc at pwi-inc.com orequivalent), 5.08 cm long and 2.54 cm wide, centered across the top 2.54cm width of sample on the end of the sample which has been stretched toinitiated delamination, Apply pressure to bond the tape to the sample.In the case of a bi-laminate, the tape is placed on the film surface. Inthe case of a tri-laminate, the tape is placed on the 2.54 cm widesurface opposite to the side for which the laminate bond strength is tobe measured. This tape will support the film portion of the t-peelsample after steps 4 and 5 are complete. (4) Carefully pull the fibersoff of the film on the side of the sample that does not have tape, inthe 6.45 cm² area between the pen mark and the end of the sample. Forsamples that are well bonded, this can be achieved by gently abradingthe sample with a rubber eraser in the approximate direction toward thepen mark. (5) Carefully peel the nonwoven off of the film to the penmark. (6) Place a second piece of tape, 5.08 cm long and 2.54 cm wide,centered across the top 2.54 cm width of the nonwoven fibers that havebeen intentionally delaminated from the sample to form the nonwovenportion of the T-peel sample. A minimum of five samples is used todetermine the average test value. To perform the T-peel test, mount thesample into the grips in a T-peel configuration with the nonwovenportion of the T-peel sample mounted in the upper grip and the filmportion of the T-peel sample mounted into the bottom grip. The specimenis mounted into the grips in a manner such that there is minimal slackand the force measured is less than about 0.02N. The crosshead moves upat a constant crosshead speed of 30.5 cm/min and the sample is peeleduntil the respective materials (nonwoven fibers and film) separatecompletely. The force and extension data are acquired at a rate of 50 Hzduring the peel. The peak force (N/cm) during the first 50 mm ofextension is reported as the Mode I peel force. Typical Mode I peelvalues for a well bonded laminate used in absorbent articles of thepresent invention are from about 1.0 N/cm to about 2.5 N/cm fornon-activated samples and from about 0.5 N/cm to about 2.0 N/cm foractivated samples.

Two Cycle Hysteresis Test

This method is used to determine properties that may correlate with theforces experienced by the consumer during application of the productcontaining the extrusion bonded laminate and how the product fits onceit is applied.

The two cycle hysteresis test method is performed at room temperature(23° C. ±2° C.). The material to be tested is cut into a substantiallyrectilinear shape. Sample dimensions are selected to achieve therequired strain with forces appropriate for the instrument. Suitablesample dimensions are approximately 25.4 mm wide by approximately 76.2mm long. Shorter specimens may be used, however, if materialavailability precludes specimens 76.2 mm in length. The sample isselected and mounted such that the direction of elongation in the testmethod is perpendicular to the width of the sample, such that it can beelongated to a length of at least the maximum percent strain of thehysteresis test. Suitable instruments, grips, grip faces, software fordata acquisition, calculations and reports and definition of percentstrain are described in the Tensile Test (Mode II) method section above.

The load cell is selected so that the forces measured fall between 10%and 90% of the capacity of the load cell or the force range used.Typically a 25 N or 100N load cell is used. The fixtures and grips areinstalled. The instrument is calibrated according to the manufacturer'sinstructions. The distance between the line of gripping force (gaugelength, as described in the Tensile test-Mode II) is 2.54 cm, which ismeasured with a steel ruler held beside the grips. The force reading onthe instrument is zeroed to account for the mass of the fixture andgrips. The samples are equilibrated at 23° C. ±2° C. for a minimum ofone hour before testing. The mass, length and width of the specimen aremeasured before testing and are used to calculate the basis weight ofthe specimen in grams per square meter (gsm). A minimum of five samplesis used to determine the average test values. The specimen is mountedinto the grips in a manner such that there is minimal slack and theforce measured is less than 0.02N. The first segment of the two cyclehysteresis test method is a gauge adjustment step using a 5 gram preloadslack adjustment. The engineering tensile engineering strain γ_(tensile)is defined in the Tensile Test Method section above and with a slackadjustment preload segment, L₀ is the adjusted gauge length, L is thestretched length and γ_(tensile) is in units of percent. The Two Cycle

Hysteresis Test is done using the following segments:

(1) Slack adjustment: Move the crosshead at 13 mm/min. until thespecified 5 gf slack adjustment preload is achieved. The distancebetween the lines of gripping force at the 5 gf slack adjustment preloadis the adjusted gauge length.

(2) Move the crosshead to achieve the specified percent engineeringstrain (i.e., engineering strain=130%) at a constant crosshead speed of254 mm/min. For example, if the adjusted gauge length from segment 1 is26.00 mm, the sample is stretched to 59.80 mm and the % engineeringstrain=((59.80/26.00)−1)*100=130%.

(3) Hold the sample for 30 seconds at the specified percent engineeringstrain (i.e., engineering strain=130%).

(4) Reduce engineering strain to 0% engineering strain (i.e., returngrips to adjusted gauge length) at a constant crosshead speed of 254mm/min.

(5) Hold the sample for 60 seconds at 0% engineering strain. (segments 1to 5 complete Cycle 1)

(6) Repeat segments 2 through 5 to complete the second cycle of the TwoCycle Hysteresis Test.

The method reports Cycle 1 load forces at 100% engineering strain and130% engineering strain (from segment 2), Cycle 1 unload force at 50%engineering strain and 30% engineering strain (from segment 4), percentset and force relaxation. The forces are reported in N/cm, where cm isthe width of the sample. The percent set is defined as the percentengineering strain after the start of the second load cycle (fromsegment 6) where a force of 7 grams is measured (percent set load=7grams).

Force relaxation is the reduction in force during the hold in segment 3and is reported as a percent. Percent force relaxation is calculatedfrom the forces measured at 130% engineering strain during Cycle 1 andis equal to 100*[((initial force at 130% engineering strain)−(force at130% engineering strain after the 30 second hold))/(initial force at130% engineering strain)].

For different sample dimensions, the crosshead speed is adjusted tomaintain the appropriate strain rate for each portion of the test. Forexample; a crosshead speed of 127 mm/min would be used in segments 2, 4and 6 for a sample gauge length of 12.7 mm and a crosshead speed of 381mm/min would be used in segments 2, 4 and 6 for a sample gauge length of38.1 mm. Additionally, for samples with different widths, the slackpreload force (5 grams per 2.54 cm width=1.97 g/cm) and the percent setload force (7 grams per 2.54 cm width=2.76 g/cm) must be adjusted forthe different sample width. The Two Cycle Hysteresis Test may also bemodified depending on the expected properties of the material tested.For example, if the sample is not capable of being elongated to 130%engineering strain without breaking, the sample is to be elongated to100% engineering strain. And, if the sample is not capable of beingelongated to 100% engineering strain, the sample is to be elongated to70% engineering strain. In the latter two cases (elongation to 100% or70% strain), force relaxation is determined at the maximum elongation ofCycle 1 as defined above for elongation of 130% engineering strain. TheTwo Cycle Hysteresis Test may also be modified to enable measurement ofhysteresis forces of a laminate after stretching to a higher engineeringstrain by using a specified percent engineering strain of 165% or 200%.This may be useful when the laminate of the absorbent article stretchesto 165% engineering strain, or to 200% engineering strain duringapplication or use. The Two Cycle Hysteresis Test may also be modifiedto enable measurement of hysteresis forces of a laminate at elevatedtemperatures that may be experienced during use of the absorbentarticle, for example at about 34 degrees or about 38 degrees Celsius.Measurements at elevated temperatures are done in an environmentalchamber, and the laminate sample is equilibrated at the test temperaturefor 5 minutes before measuring the hysteresis forces.

Permanent Set

See the Two Cycle Hysteresis Test immediately above.

Percent Strain Recovery Test (PSRT)—

The Percent Strain Recovery Test (PSRT), is used to quantify how amaterial recovers after deformation, as it relates to post activationset (e.g. how does the dimension of the material change due toactivation). The Two Cycle Hysteresis Test above was modified by (1)eliminating the 30 second hold in step 3 at the specified maximumengineering strain and by (2) testing material at several maximumpercent engineering strains (100%, 200%, 245% and 324%), includinghigher strains similar to strains used for activation. Fresh samples areused for each maximum percent engineering strain tested. The percent setis defined as the percent engineering strain after the start of thesecond load cycle (from segment 6) where a force of 7 grams is measured(percent set load=7 grams). The result reported, Percent Recovery ofStrain (PRS), is calculated using the equation below:

PRS=100×[1−(percent set/maximum percent engineering strain)]

The PRS is reported for each maximum strain tested.

Pin Holes

Stretch laminates are visually inspected for the presence of pin holeswith the laminate stretched to 20% engineering strain (for example, alaminate of 100 mm width is stretched to 120 mm width). The defects arecategorized by type, as either a “hole” or a “spot”. A “hole” is definedas an area of the laminate in which the multilayer film has a completefailure, with the visual appearance of a hole or a tear. A “spot” isdefined as an area of the laminate with a partial failure of the film,with the visual appearance of a hole or tear in some, but not all layersof the multilayered film. The largest dimension of each hole is measuredwith a steel rule, with the multilayered laminate stretched to 20%engineering strain under magnification (for example, using illuminatedmagnifier KFM 17113 available from LUXO, Elmsford, N.Y., 10523). Theholes are categorized by size based on the length of the largestdimension of the hole; tiny (<0.5 mm), small (>0.5mm and <1 mm), medium(>1 mm and <2 mm), large (>2 mm and <3 mm) and extra large (>3 mm). Whensufficient material is available, the number of holes per square meterof material (holes/m²) can be calculated. For example, 20 samples, eachwith a dimension of 100 mm by 100 mm, have a combined total area of 0.2m². The total number of holes in the 20 samples can be multiplied byfive to calculate the number of holes/m².

Breathability (Water Vapor Transmission Rate, MVTR)

Water Vapor Transmission Rate (MVTR) is measured by the INDA/EDANAWorldwide Strategic Partners WSP 70.4 (08) standard test method using aPermatran-W model 100K (MOCON, Minneapolis, Minn.), a test temperatureof 37° C., a nitrogen flow rate of 120 SCCM, a relative humidity of 60%±1.5%. The instrument is calibrated according to the standard testmethod and a standard reference film (S/N 1008WK089) is tested to verifythe equipment is operating properly. The skin facing side of themultilayer laminate is oriented toward the water for testing. A minimumof five samples are tested and an average MVTR is reported in gm/m²/day,to the nearest 1 gm/m²/day.

Regarding all numerical ranges disclosed herein, it should be understoodthat every maximum numerical limitation given throughout thisspecification includes every lower numerical limitation, as if suchlower numerical limitations were expressly written herein. In addition,every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Further, everynumerical range given throughout this specification will include everynarrower numerical range that falls within such broader numerical rangeand will also encompass each individual number within the numericalrange, as if such narrower numerical ranges and individual numbers wereall expressly written herein.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent article comprising a topsheet; anouter cover; at least one chassis component; and an absorbent coredisposed between the topsheet and the outer cover; wherein at least oneof the outer cover or the at least one chassis component comprises adual bilaminate comprising a first bilaminate, a second bilaminate, andan adhesive layer inbetween the first bilaminate and the secondbilaminate; wherein the first bilaminate and the second bilaminate eachcomprise at least one nonwoven and at least one multilayer filmcomprising at least three film layers; and wherein the dual bilaminatehas at most about 90 grams per square meter basis weight; wherein themultilayer film comprises at least one inner layer comprising one ormore elastomeric components; wherein the multilayer film comprises twoouter layers; wherein the nonwoven and the multilayer film of both thefirst bilaminate and the second bilaminate are bonded together via anextrusion lamination process; wherein the second bilaminate is disposedon from about 10% to about 100% of the area of the first bilaminate; andwherein the dual bilaminate has a percent set of less than 20% asmeasured by the Two Cycle Hysteresis Test having a 130% strain firstloading cycle and a 130% strain second loading cycle.
 2. The absorbentarticle of claim 1, wherein at least one of the inner layers and/oradditional polymer layer(s) of the multilayer film in the firstbilaminate and/or the second bilaminate comprises one or more ofelastomeric polymers selected from the group consisting of polyolefinicelastomer, styrene block copolymers, copolymer of polypropylene andpolyethylene, and combinations and/or blends thereof.
 3. The absorbentarticle of claim 2, wherein the elastomeric polymer is the styrene blockcopolymer, and wherein the styrene block copolymer is an SEEPS blockcopolymer and/or an SEPS block copolymer.
 4. The absorbent article ofclaim 1, wherein at least one of the two outer layers in the firstbilaminate and/or the second bilaminate is a blend of two ethylene richco-polymers, and wherein the weight % ethylene content is about 10% toabout 97%.
 5. The absorbent article of claim 1, wherein the multilayerfilm comprises at least one additional polymeric layer that is disposednext to the at least one inner layer; and wherein the at least oneadditional polymeric layer in the first bilaminate and/or the secondbilaminate comprises a plastoelastic component.
 6. The absorbent articleof claim 1, wherein the polymeric material comprises at least 50% byweight polyolefin.
 7. The absorbent article of claim 1, wherein the dualbilaminate is printed, embossed, apertured, and/or textured.
 8. Theabsorbent article of claim 1 wherein the at least one -chassis componentcomprises a dual bilaminate, and wherein the at least one chassiscomponent is selected from the group consisting of a pair of back earlaminates, an outer cover, a pair of side panels, a front waist panel,and a back waist panel.
 9. The absorbent article of claim 1, wherein themulti-layer film of each of the first and second bilaminates has a basisweight from about 10 gsm to about 40 gsm.
 10. The absorbent article ofclaim 1, wherein the at least one nonwoven is extensible.
 11. Theabsorbent article of claim 1, wherein the first bilaminate and/or thesecond bilaminate has a coextruded structure A1B1C1B2A2 and comprises atleast one polyolefin elastomer in the B1 and B2 layers, and at least onestyrene block copolymer elastomer in the C1 layer.
 12. The absorbentarticle of claim 1, wherein the at least one nonwoven comprisesbicomponent fibers, the fibers comprising a core and a sheath, whereinthe sheath comprises polyethylene and the core comprises polypropylene.13. The absorbent article of claim 1, wherein the at least one nonwovencomprises multilobal fibers and/or side-by-side bicomponent fibers. 14.The absorbent article of claim 1, wherein the at least one nonwoven andthe at least one multilayer film are bonded together by a styrene blockcopolymer-based adhesive or a polyolefin-based adhesive.
 15. Theabsorbent article of claim 1, wherein the first bilaminate and thesecond bilaminate are bonded together by an adhesive, via thermal orpressure or ultrasonic bonding, or via fusion during hot pinholeformation.
 16. The absorbent article of claim 1, wherein the secondbilaminate is prestrained prior to being combined with the firstbilaminate.
 17. The absorbent article of claim 1, wherein the dualbilaminate comprises a stiffener.
 18. The absorbent article of claim 1,wherein the first bilaminate and the second bilaminate are activated inthe machine direction and/or the cross direction.
 19. The absorbentarticle of claim 18, wherein the level of stretch of the activated dualbilaminate (% engineering strain at 1 N/cm force, as measured by thetensile test) is from about 10% strain to about 300% strain.
 20. Theabsorbent article of claim 1, wherein the second bilaminate has apercent recovery of strain (PRS) greater than or equal to the firstbilaminate.